Chrysler Voyager Service Manual GS 1999-1996

CHRYSLER
INTERNATIONAL
SERVICE MANUAL
1998
CHRYSLER VOYAGER
NO PART OF THI S PUBLI CATI ON MAY BE
REPRODUCED, STORED I N A RETRI EVAL
SYSTEM, OR TRANSMI TTED, I N ANY FORM OR
BY ANY MEANS, ELECTRONI C, MECHANI CAL,
PHOTOCOPYI NG, RECORDI NG, OR OTHERWI SE,
WI THOUT THE PRI OR WRI TTEN PERMI SSI ON
OF CHRYSLER I NTERNATI ONAL.
Chrysler International reserves the right to make changes in design or to
make additions to or improvements in its products without imposing any obli-
gations upon itself to install them on its products previously manufactured.
Litho in U.S.A. Copyright 1976 Chrysler Corporation
FOREWORD
The i nformati on contai ned i n thi s servi ce manual has been prepared for the professi onal automoti ve tech-
ni ci an i nvol ved i n dai l y repai r operati ons. Thi s manual does not cover theory of operati on, whi ch i s addressed
i n servi ce trai ni ng materi al . I nformati on descri bi ng the operati on and use of standard and opti onal equi pment
i s i ncl uded i n the Owner s Manual provi ded wi th the vehi cl e.
I nformati on i n thi s manual i s di vi ded i nto groups. These groups contai n general i nformati on, di agnosi s,
testi ng, adjustments, removal , i nstal l ati on, di sassembl y, and assembl y procedures for the systems and compo-
nents. To assi st i n l ocati ng a group ti tl e page, use the Group Tab Locator on the fol l owi ng page. The sol i d bar
after the group ti tl e i s al i gned to a sol i d tab on the fi rst page of each group. The fi rst page of the group has
a contents secti on that l i sts major topi cs wi thi n the group. I f you are not sure whi ch Group contai ns the i nfor-
mati on you need, l ook up the Component/System i n the al phabeti cal i ndex l ocated i n the rear of thi s manual .
Ti ghteni ng torques are provi ded as a speci fi c val ue throughout thi s manual . Thi s val ue represents the
mi dpoi nt of the acceptabl e engi neeri ng torque range for a gi ven fastener appl i cati on. These torque val ues are
i ntended for use i n servi ce assembl y and i nstal l ati on procedures usi ng the correct OEM fasteners. When
repl aci ng fasteners, al ways use the same type (part number) fastener as removed.
Chrysl er I nternati onal reserves the ri ght to change testi ng procedures, speci fi cati ons, di agnosi s, repai r
methods, or vehi cl e wi ri ng at any ti me wi thout pri or noti ce or i ncurri ng obl i gati on.
GROUP TAB LOCATOR
Introduction
0
Lubrication and Maintenance
2
Suspension
5
Brakes
6
Clutch
7
Cooling System
8A
Battery
8B
Starting System
8E
Instrument Panel and Systems
8H
Vehicle Speed Control System
8K
Wiper and Washer Systems
8L
Lamps
8Q
Vehicle Theft/Security Systems
8U
Chime Warning/Reminder System
8W
Wiring Diagrams
9
Engine
13
Frame and Bumpers
14
Fuel System2.5L Diesel Engine/2.0L Gas Engine
19
Steering
21
A598 Manual Transaxle
23
Body
24
Heating and Air Conditioning
25
Emission Control System
INTRODUCTION
CONTENTS
page page
GENERAL INFORMATION
BODY CODE PLATE . . . . . . . . . . . . . . . . . . . . . . 1
FASTENER IDENTIFICATION . . . . . . . . . . . . . . . . 4
INTERNATIONAL VEHICLE CONTROL AND
DISPLAY SYMBOLS . . . . . . . . . . . . . . . . . . . . . 4
METRIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . 7
TORQUE REFERENCES . . . . . . . . . . . . . . . . . . . 7
VEHICLE IDENTIFICATION NUMBER . . . . . . . . . . 1
VEHICLE SAFETY CERTIFICATION LABEL . . . . . 1
VIN CHECK DIGIT . . . . . . . . . . . . . . . . . . . . . . . . 1
GENERAL INFORMATION
VEHICLE SAFETY CERTIFICATION LABEL
A vehi cl e safety certi fi cati on l abel (Fi g. 1) i s l ocated
on the rear shut face of the dri vers door. Thi s l abel
i ndi cates date of manufacture (month and year),
Gross Vehi cl e Wei ght Rati ng (GVWR), Gross Axl e
Wei ght Rati ng (GAWR) front, Gross Axl e Wei ght Rat-
i ng (GAWR) rear and the Vehi cl e I denti fi cati on Num-
ber (VI N). The Month, Day and Hour of manufacture
i s al so i ncl uded.
When i t i s necessary to contact the manufacturer
regardi ng servi ce or warranty, the i nformati on on the
Vehi cl e Safety Certi fi cati on Label woul d be requi red.
VEHICLE IDENTIFICATION NUMBER
The Vehi cl e I denti fi cati on Number (VI N) can be
vi ewed through the wi ndshi el d at the upper l eft cor-
ner of the i nstrument panel , near the l eft wi ndshi el d
pi l l ar (Fi g. 2). The VI N consi sts of 17 characters i n a
combi nati on of l etters and numbers that provi de spe-
ci fi c i nformati on about the vehi cl e. Refer to VI N
Code Breakdown Chart for decodi ng i nformati on.
VIN CHECK DIGIT
To protect the consumer from theft and possi bl e
fraud, the manufacturer i s requi red to i ncl ude a
Check Di gi t at the ni nth posi ti on of the Vehi cl e I den-
ti fi cati on Number. The check di gi t i s used by the
manufacturer and government agenci es to veri fy the
authenti ci ty of the vehi cl e and offi ci al documenta-
ti on. The formul a to use the check di gi t i s not
rel eased to the general publ i c.
BODY CODE PLATE
LOCATION AND DECODING
The Body Code Pl ate (Fi g. 3) i s l ocated i n the
engi ne compartment on the radi ator cl osure panel
crossmember. There are seven l i nes of i nformati on on
the body code pl ate. Li nes 4, 5, 6, and 7 are not used
to defi ne servi ce i nformati on. I nformati on reads from
l eft to ri ght, starti ng wi th l i ne 3 i n the center of the
pl ate to l i ne 1 at the bottom of the pl ate.
Fig. 1 Vehicle Safety Certification Label
Fig. 2 Vehicle Identification Number (VIN Plate)
NS INTRODUCTION 1
BODY CODE PLATE LINE 3
DIGITS 1 THROUGH 12
Vehi cl e Order Number
DIGITS 13 THROUGH 17
Open space
DIGITS 18 AND 19
Vehi cl e Shel l Li ne
NS
DIGIT 20
Carl i ne
FWD
H = Pl ymouth
K = Dodge
S = Chrysl er
AWD
C = Chrysl er
D = Dodge
P = Pl ymouth
VIN CODE BREAKDOWN CHART
POSITION INTERPRETATION CODE = DESCRIPTION
1 Country of Origin 1 = United States
2 = Canada
2 Make B = Dodge
C = Chrysler
P = Plymouth
3 Vehicle Type 4 = Multipurpose Pass. Vehicle
4 Gross Vehicle Weight Rating G = 2268 - 2721 kg (5001 - 6000 lbs)
5 Car Line P = Chrysler, Town & Country
P = Dodge, Caravan/Grand Caravan
P = Plymouth, Voyager/Grand Voyager
T = AWD Chrysler, Town & Country
T = AWD Dodge, Grand Caravan
T = AWD Plymouth, Grand Voyager
6 Series 2 = FWD Caravan/Grand Caravan, Voyager/
Grand Voyager
4 = Caravan SE/Grand Caravan SE, Voyager
SE/Grand Voyager SE
5 = Caravan LE or ES/Grand Caravan LE or ES,
Voyager LE/Grand Voyager LE, Town & Country
LX
6 = Town & Country LXI
7 Body Style 4 = Long Wheel Base
5 = Short Wheel Base
8 Engine B = 2.4 L 4 cyl. MPI 16-VALVE DOHC
3 = 3.0 L 6 cyl. gas MPI
R = 3.3L 6 cyl. gas MPI
L = 3.8 L 6 cyl. gas MPI
9 Check Digit See explanation in this section.
10 Model Year V = 1997
11 Assembly Plant B = St. Louis South
R = Windsor
12 thru 17 Sequence Number 6 digit number assigned by assembly plant.
2 INTRODUCTION NS
GENERAL INFORMATION (Continued)
DIGIT 21
Pri ce Cl ass
H = Hi ghl i ne
L = Lowl i ne
P = Premi um
S = Luxury
DIGITS 22 AND 23
Body Type
53 = Long Wheel Base
DIGITS 1, 2 AND 3
Pai nt procedure
DIGIT 4
Open Space
DIGITS 5 THROUGH 8
Pri mary pai nt
See Group 23, Body for col or codes.
DIGIT 9
Open Space
Secondary Pai nt
DIGIT 14
Open Space
I nteri or Tri m Code
DIGIT 19
Open Space
DIGITS 20, 21, AND 22
Engi ne Code
EDZ = 2.4L 4 cyl . DOHC Gasol i ne
EFA = 3.0L 6 cyl . Gasol i ne
EGA = 3.3L 6 cyl . Gasol i ne
EGH = 3.8L 6 cyl . Gasol i ne
DIGITS 1, 2, AND 3
Transaxl e Codes
DGB = 31TH 3-Speed Automati c Transaxl e
DGL = 41TE 4-speed El ectroni c Automati c Tran-
saxl e
DGM = 31TH 3-Speed Automati c Transaxl e
DIGIT 4
Open Space
DIGIT 5
Market Code
C = Canada
B = I nternati onal
M = Mexi co
U = Uni ted States
DIGIT 6
Open Space
DIGITS 7 THROUGH 23
Vehi cl e I denti fi cati on Number
Refer to Vehi cl e I denti fi cati on Number (VI N)
paragraph for proper breakdown of VI N code.
IF TWO BODY CODE PLATES ARE REQUIRED
The l ast code shown on ei ther pl ate wi l l be fol -
l owed by END. When two pl ates are requi red, the
l ast code space on the fi rst pl ate wi l l i ndi cate (CTD)
When a second pl ate i s requi red, the fi rst four
spaces of each l i ne wi l l not be used due to overl ap of
the pl ates.
Fig. 3 Body Code Plate
NS INTRODUCTION 3
INTERNATIONAL VEHICLE CONTROL AND DISPLAY
SYMBOLS INTERNATIONAL VEHICLE CONTROL
AND DISPLAY SYMBOLS
The graphi c symbol s i l l ustrated i n the fol l owi ng
chart (Fi g. 4) are used to i denti fy vari ous i nstrument
control s. The symbol s correspond to the control s and
di spl ays that are l ocated on the i nstrument panel .
FASTENER IDENTIFICATION
THREAD IDENTIFICATION
SAE and metri c bol t/nut threads are not the same.
The di fference i s descri bed i n the Thread Notati on
chart (Fi g. 5).
GRADE/CLASS IDENTIFICATION
The SAE bol t strength grades range from grade 2
to grade 8. The hi gher the grade number, the greater
the bol t strength. I denti fi cati on i s determi ned by the
l i ne marks on the top of each bol t head. The actual
bol t strength grade corresponds to the number of l i ne
marks pl us 2. The most commonl y used metri c bol t
strength cl asses are 9.8 and 12.9. The metri c strength
cl ass i denti fi cati on number i s i mpri nted on the head of
the bol t. The hi gher the cl ass number, the greater the
bol t strength. Some metri c nuts are i mpri nted wi th a
si ngl e-di gi t strength cl ass on the nut face. Refer to the
Fastener I denti fi cati on and Fastener Strength Charts.
INTERNATIONAL CONTROL AND DISPLAY SYMBOLS
Fig. 4
Fig. 5 Thread NotationSAE and Metric
4 INTRODUCTION NS
NS INTRODUCTION 5
FASTENER STRENGTH
6 INTRODUCTION NS
METRIC SYSTEM
WARNING: USE OF AN INCORRECT FASTENER
MAY RESULT IN COMPONENT DAMAGE OR PER-
SONAL INJURY.
Fi gure art, speci fi cati ons and torque references i n
thi s Servi ce Manual are i denti fi ed i n metri c and SAE
format.
Duri ng any mai ntenance or repai r procedures, i t i s
i mportant to sal vage metri c fasteners (nuts, bol ts,
etc.) for reassembl y. I f the fastener i s not sal vage-
abl e, a fastener of equi val ent speci fi cati on shoul d be
used.
The metri c system i s based on quanti ti es of one,
ten, one hundred, one thousand and one mi l l i on (Fi g.
6).
The fol l owi ng chart wi l l assi st i n converti ng metri c
uni ts to equi val ent Engl i sh and SAE uni ts, or vi se
versa.
Refer to the Conversi on Chart to convert torque
val ues l i sted i n metri c Newton- meters (Nm). Al so,
use the chart to convert between mi l l i meters (mm)
and i nches (i n.)
TORQUE REFERENCES
I ndi vi dual Torque Charts appear at the end of
many Groups. Refer to the Standard Torque Speci fi -
cati ons Chart for torque references not l i sted i n the
i ndi vi dual torque charts.
Fig. 6 Metric Prefixes
CONVERSION FORMULAS AND EQUIVALENT VALUES
NS INTRODUCTION 7
METRIC CONVERSION
8 INTRODUCTION NS
TORQUE SPECIFICATIONS
NS INTRODUCTION 9
INTRODUCTION
CONTENTS
page page
GENERAL INFORMATION
BODY CODE PLATE . . . . . . . . . . . . . . . . . . . . . . 1
E-MARK LABEL . . . . . . . . . . . . . . . . . . . . . . . . . 1
MANUFACTURER PLATE . . . . . . . . . . . . . . . . . . 3
VEHICLE IDENTIFICATION NUMBER . . . . . . . . . 1
GENERAL INFORMATION
E-MARK LABEL
An E-mark Label (Fi g. 1) i s l ocated on the rear
shut face of the dri vers door. The l abel contai ns the
fol l owi ng i nformati on:
Date of Manufacture
Month-Day-Hour (MDH)
Vehi cl e I denti fi cati on Number (VI N)
Country Codes
Regul ati on Number
Regul ati on Amendment Number
Approval Number
VEHICLE IDENTIFICATION NUMBER
The Vehi cl e I denti fi cati on Number (VI N) can be
vi ewed through the wi ndshi el d at the upper l eft cor-
ner of the i nstrument panel next to the l eft A-pi l l ar
(Fi g. 2). The VI N consi sts of 17 characters i n a com-
bi nati on of l etters and numbers that provi de speci fi c
i nformati on about the vehi cl e. Refer to the VI N
Decodi ng I nformati on Tabl e to i nterpret VI N code.
VIN CHECK DIGIT
To protect the consumer from theft and possi bl e
fraud the manufacturer i s requi red to i ncl ude a check
Di gi t at the ni nth posi ti on of the VI N. The check
di gi t i s used by the manufacturer and government
agenci es to veri fy the authenti ci ty of the vehi cl e and
offi ci al documentati on. The formul a to use the check
di gi t i s not rel eased to the general publ i c.
BODY CODE PLATE
LOCATION AND DECODING
The Body Code Pl ate i s l ocated (Fi g. 3) i n the
crossmember. There are seven l i nes of i nformati on on
the body code pl ate. Li nes 4, 5, 6, and 7 are not used
to defi ne servi ce i nformati on. I nformati on reads from
l eft to ri ght, starti ng wi th l i ne 3 i n the center of the
pl ate to l i ne 1 at the bottom of the pl ate.
BODY CODE PLATELINE 3
DIGITS 1 THROUGH 12
Vehi cl e Order Number
Open Space
Fig. 1 E-Mark Label
Fig. 2 VIN PLATE LOCATION
NS/GS INTRODUCTION 1
Vehi cl e Shel l Car Li ne
GSYH = Voyager/Grand Voyager SE FWD
GSYP = Voyager/Grand Voyager LE FWD
GSYS = Voyager LX FWD
GSCP = Voyager/Grand Voyager LE AWD
GSCS = Voyager LX AWD
DIGIT 19
Pri ce Cl ass
H = Hi gh Li ne
P = Premi um
S = Speci al /Sport
DIGITS 20 AND 21
Body Type
53 = Long Wheel Base
BODY CODE PLATELINE 2
DIGITS 1, 2, AND 3
Pai nt Procedure
DIGIT 4
Open Space
VIN DECODING INFORMATION
POSITION INTERPRETATION CODE = DESCRIPTION
1 Country of origin 1 = United States or Austria
2 = Canada
2 Make C = Chrysler
D = Dodge
3 Vehicle Type 4 = Multipurpose Pass. Veh.
4 Gross Vehicle Weight Rating G = 2268-2721 kg (5001-6000 lbs)
5 Car Line C = Voyager/Grand Voyager AWD
Y = Voyager/Grand Voyager FWD
6 Series 4 = Voyager/Grand Voyager SE FWD
5 = Voyager/Grand Voyager LE FWD/AWD
6 = Voyager LX FWD/AWD
N = 5-Speed Manual Transmission
B = 4-Speed Automatic Transmission
7 Body Style 2 = Short Wheelbase 4-Door
3 = Short Wheelbase 3-Door
4 = Long Wheelbase Premium 4-Door
5 = Long Wheelbase Highline 4-door
7 = Short Wheelbase Commercial Van
8 Engine B = 2.4 L 4cyl. MPI 16-Valve DOHC
C = 2.0L 4cyl. MPI 16-Valve SOHC
M = 2.5L 4cyl Turbo Diesel (Intercooler)
R = 3.3 L 6 cyl. gas MPI
L = 3.8 L 6 cyl. gas MPI
9 Check Digit See explanation in this section.
10 Model Year W = 1998
11 Assembly Plant B = St. Louis South, U.S.A.
R = Windsor, Canada
U = Graz, Austria
12 Build Sequence 6 Digit number assigned by assembly plant
2 INTRODUCTION NS/GS
DIGITS 5 THROUGH 8
Pri mary Pai nt
See Group 23, Body for col or codes.
DIGIT 9
Open Space
Secondary Pai nt
DIGIT 14
Open Space
I nteri or Tri m Code
DIGIT 19
Open Space
Engi ne Code
ECB = 2.0L 4cyl 16 val ve SOHC gasol i ne
EDZ = 2.4 L 4 cyl . 16 val ve DOHC gasol i ne
ENC = 2.5 L 4 cyl . Turbo Di esel (I ntercool er)
EGA = 3.3 L 6 cyl . gasol i ne
EGH = 3.8 L 6 cyl . gasol i ne
DIGITS 1, 2, AND 3
Transaxl e Codes
DGL = 41TE 4-speed El ectroni c Automati c Tran-
saxl e
DD3 = A-598 5speed Manual Transaxl e
DIGIT 4
Open Space
DIGIT 5
Market Code
B = I nternati onal
M = Mexi co
DIGIT 6
Open Space
DIGITS 7 THROUGH 23
Vehi cl e I denti fi cati on Number (VI N)
Refer to Vehi cl e I denti fi cati on Number (VI N) para-
graph for proper breakdown of VI N code.
IF TWO BODY CODE PLATES ARE REQUIRED
The l ast code shown on ei ther pl ate wi l l be fol -
l owed by END. When two pl ates are requi red, the
l ast code space on the fi rst pl ate wi l l i ndi cate conti n-
ued (CTD).
When a second pl ate i s requi red, the fi rst four
spaces of each l i ne wi l l not be used due to overl ap of
the pl ates.
MANUFACTURER PLATE
The Manufacturer Pl ate (Fi g. 4) i s l ocated i n the
crossmember adjacent to the Body Code Pl ate. The
pl ate contai ns fi ve l i nes of i nformati on:
1. Vehi cl e I denti fi cati on Number (VI N)
2. Gross Vehi cl e Mass (GVM)
3. Gross Trai n Mass (GTM)
4. Gross Front Axl e Rati ng (GFAR)
5. Gross Rear Axl e Rati ng (GRAR)
Fig. 3 Body Code Plate
Fig. 4 Manufacturer Plate
NS/GS INTRODUCTION 3
LUBRICATION AND MAINTENANCE
CONTENTS
page page
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . 1
JUMP STARTING, HOISTING AND TOWING . . . . 7
MAINTENANCE SCHEDULES . . . . . . . . . . . . . . . . 3
GENERAL INFORMATION
INDEX
page page
GENERAL INFORMATION
CLASSIFICATION OF LUBRICANTS . . . . . . . . . . . 1
FLUID CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . 2
INTERNATIONAL SYMBOLS . . . . . . . . . . . . . . . . 1
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . 1
PARTS AND LUBRICANT
RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . 1
GENERAL INFORMATION
INTRODUCTION
Servi ce and mai ntenance procedures for compo-
nents and systems l i sted i n Schedul e A or B can be
found by usi ng the Group Tab Locator i ndex at the
front of thi s manual . I f i t i s not cl ear whi ch group
contai ns the i nformati on needed, refer to the i ndex at
the back of thi s manual .
There are two mai ntenance schedul es that show
proper servi ce based on the condi ti ons that the vehi -
cl e i s subjected to.
Schedul e A, l i sts schedul ed mai ntenance to be
performed when the vehi cl e i s used for general trans-
portati on.
Schedul e B, l i sts mai ntenance i nterval s for vehi -
cl es that are operated under the condi ti ons l i sted at
the begi nni ng of the Mai ntenance Schedul e secti on.
Use the schedul e that best descri bes your dri vi ng
condi ti ons.
Where ti me and mi l eage are l i sted, fol l ow the
i nterval that occurs fi rst.
PARTS AND LUBRICANT RECOMMENDATIONS
When servi ce i s requi red, Chrysl er Corporati on
recommends that onl y Mopar brand parts, l ubri -
cants and chemi cal s be used. Mopar provi des the
best engi neered products for servi ci ng Chrysl er Cor-
porati on vehi cl es.
INTERNATIONAL SYMBOLS
Chrysl er Corporati on uses i nternati onal symbol s to
i denti fy engi ne compartment l ubri cant and fl ui d
i nspecti on and fi l l l ocati ons (Fi g. 1).
CLASSIFICATION OF LUBRICANTS
Onl y l ubri cants that are endorsed by the fol l owi ng
organi zati on shoul d be used to servi ce a Chrysl er
Corporati on vehi cl e.
Soci ety of Automoti ve Engi neers (SAE)
Ameri can Petrol eum I nsti tute (API ) (Fi g. 2)
Nati onal Lubri cati ng Grease I nsti tute (NLGI )
(Fi g. 3)
Fig. 1 International Symbols
NS LUBRICATION AND MAINTENANCE 0 - 1
ENGINE OIL
SAE VISCOSITY RATING INDICATES ENGINE OIL VISCOSITY
An SAE vi scosi ty grade i s used to speci fy the vi s-
cosi ty of engi ne oi l . SAE 30 speci fi es a si ngl e vi scos-
i ty engi ne oi l . Engi ne oi l s al so have mul ti pl e
vi scosi ti es. These are speci fi ed wi th a dual SAE vi s-
cosi ty grade whi ch i ndi cates the col d-to-hot tempera-
ture vi scosi ty range.
SAE 30 = si ngl e grade engi ne oi l .
SAE 10W-30 = mul ti pl e grade engi ne oi l .
API QUALITY CLASSIFICATION
The API Servi ce Grade speci fi es the type of perfor-
mance the engi ne oi l i s i ntended to provi de. The API
Servi ce Grade speci fi cati ons al so appl y to energy con-
servi ng engi ne oi l s.
Use engi ne oi l s that are API Servi ce Certi fi ed.
5W-30 and 10W-30 MOPAR engi ne oi l s conform to
speci fi cati ons.
Refer to Group 9, Engi ne for engi ne oi l speci fi ca-
ti on.
GEAR LUBRICANTS
SAE rati ngs al so appl y to mul ti pl e grade gear
l ubri cants. I n addi ti on, API cl assi fi cati on defi nes the
l ubri cants usage.
LUBRICANTS AND GREASES
Lubri cati ng grease i s rated for qual i ty and usage
by the NLGI . Al l approved products have the NLGI
symbol (Fi g. 3) on the l abel . At the bottom NLGI
symbol i s the usage and qual i ty i denti fi cati on l etters.
Wheel beari ng l ubri cant i s i denti fi ed by the l etter
G. Chassi s l ubri cant i s i denti fi ed by the l atter L.
The l etter fol l owi ng the usage l etter i ndi cates the
qual i ty of the l ubri cant. The fol l owi ng symbol s i ndi -
cate the hi ghest qual i ty.
FLUID CAPACITIES
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . .76 L (20 gal .)
Engi ne Oi l , Wi th Fi l ter . . . . . . . . . . . .4.3 L (4.5 qts.)
Engi ne Oi l , W/O Fi l ter. . . . . . . . . . . . .3.8 L (4.0 qts.)
Cool i ng System 2.4L Engi ne . . . . . . . .9.0 L (9.5 qts.)
Cool i ng System 3.OL Engi ne . . . . . . .9.5 L (10.5 qts.)
Cool i ng System 3.3 or 3.8L Engi ne . .9.5 L (10.5 qts.)
Automati c Transaxl e Servi ce Fi l l . . . . .3.8 L (4.0 qts.)
Automati c Transaxl e
31TH/O-haul Fi l l . . . . . . . . . . . . . . .8.0 L (8.5 qts.)
Automati c Transaxl e
41TE/O-haul Fi l l . . . . . . . . . . . . . . .8.6 L (9.1 qts.)
Power Steeri ng . . . . . . . . . . . . . . . . .0.81 L (1.7 pts.)
Fig. 2 API Symbol
Fig. 3 NLGI Symbol
0 - 2 LUBRICATION AND MAINTENANCE NS
MAINTENANCE SCHEDULES
INDEX
page page
GENERAL INFORMATION
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . 3
SCHEDULE A . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SCHEDULE B . . . . . . . . . . . . . . . . . . . . . . . . . . 4
UNSCHEDULED INSPECTION . . . . . . . . . . . . . . . 3
GENERAL INFORMATION
INTRODUCTION
Servi ce and mai ntenance procedures for compo-
nents and systems l i sted i n Schedul e A or B can be
found by usi ng the Group Tab Locator i ndex at the
front of thi s manual . I f i t i s not cl ear whi ch group
contai ns the i nformati on needed, refer to the i ndex at
the back of thi s manual .
There are two mai ntenance schedul es that show
proper servi ce based on the condi ti ons that the vehi -
cl e i s subjected to.
Schedul e A, l i sts schedul ed mai ntenance to be
performed when the vehi cl e i s used for general trans-
portati on.
Schedul e B, l i sts mai ntenance i nterval s for vehi -
cl es that are operated under the condi ti ons l i sted at
the begi nni ng of the Mai ntenance Schedul e secti on.
Use the schedul e that best descri bes your dri vi ng
condi ti ons.
Where ti me and mi l eage are l i sted, fol l ow the
i nterval that occurs fi rst.
UNSCHEDULED INSPECTION
At Each Stop for Fuel
Check engi ne oi l l evel , add as requi red.
Check wi ndshi el d washer sol vent and add i f
requi red.
Once a Month
Check ti re pressure and l ook for unusual wear
or damage.
I nspect battery and cl ean and ti ghten termi nal s
as requi red.
Check fl ui d l evel s of cool ant reservoi r, brake
master cyl i nder, power steeri ng and transaxl e and
add as needed.
Check al l l i ghts and al l other el ectri cal i tems for
correct operati on.
Check rubber seal s on each si de of the radi ator
for proper fi t.
At Each Oil Change
I nspect exhaust system.
I nspect brake hoses
I nspect the CV joi nts and front suspensi on com-
ponents
Rotate the ti res at each oi l change i nterval
shown on Schedul e A (7,500 mi l es) or every other
i nterval shown on Schedul e B (6,000 mi l es).
Check the cool ant l evel , hoses, and cl amps.
I f your mi l eage i s l ess than 7,500 mi l es (12 000
km) yearl y, repl ace the engi ne oi l fi l ter at each oi l
change.
Repl ace engi ne oi l fi l ter on 2.4L engi nes.
SCHEDULE A
7,500 Miles (12 000 km) or at 6 months
Change engi ne oi l .
Repl ace engi ne oi l fi l ter.
I nspect brake l i ni ngs.
Change automati c transmi ssi on fl ui d.
Replace air cleaner element.
I nspect ti e rod ends and boot seal s.
Fl ush and repl ace engi ne cool ant at 36 months,
regardl ess of mi l eage.
Fl ush and repl ace engi ne cool ant i f not done at
36 months.
Check PCV valve and replace, if necessary.
*
I nspect serpenti ne dri ve bel t, repl ace i f neces-
sary.
sary. Thi s mai ntenance i s not requi red i f bel t was
previ ousl y repl aced.
Fl ush and repl ace engi ne cool ant i f i t has been
30,000 mi l es (48 000 km) or 24 months si nce l ast
change.
change.
Check PCV valve and replace, if necessary.
Not required if previously changed. *
100,000 Miles (160,000 km)
Replace spark plugs on 3.3L and 3.8L
engines.
Replace ignition cables on 3.3L and 3.8L
engines.
change.
change.
Repl ace automati c transmi ssi on fl ui d.
Replace engine air cleaner element.
Check and replace PCV valve, if necessary.
*
I nspect serpenti ne dri ve bel t. Not requi red i f
repl aced at 75,000, 90,000 or 105,000 mi l es.
* Thi s mai ntenance i s recommended by Chrysl er to
the owner but i s not requi red to mai ntai n the war-
ranty on the PCV val ve.
** I f Cal i forni a vehi cl e, thi s mai ntenance i s recom-
mended by Chrysl er to the owner but i s not requi red
to mai ntai n the warranty of the ti mi ng bel t.
SCHEDULE B
3,000 Miles (5 000 km)
6,000 Miles (10 000 km)
9,000 Miles (14 000 km)
12,000 Miles (19 000 km)
15,000 Miles (24 000 km)
Inspect air cleaner element. Replace as
necessary.
Drai n and refi l l automati c transmi ssi on fl ui d
and repl ace fi l ter. Adjust bands, i f so equi pped. (See
note)
Change AWD powertransfer fl ui d uni t.
18,000 Miles (29 000 km)
21,000 Miles (34 000 km)
Check AWD overrunni ng cl utch and rear carri er
fl ui d.
24,000 Miles (38 000 km)
27,000 Miles (43 000 km)
30,000 Miles (48 000 km)
Inspect PCV valve. Replace as necessary. *
note)
Change AWD power transfer uni t fl ui d.
33,000 Miles (53 000 km)
36,000 Miles (58 000 km)
39,000 Miles (62 000 km)
42,000 Miles (67 000 km)
Change AWD overrunni ng cl utch and rear car-
ri er fl ui d.
45,000 Miles (72 000 km)
necessary.
note)
48,000 Miles (77 000 km)
51,000 Miles (82 000 km)
Fl ush and repl ace engi ne cool ant.
54,000 Miles (86 000 km)
57,000 Miles (91 000 km)
60,000 Miles (96 000 km)
Inspect PCV valve, replace if necessary. *
sary.
note)
63,000 Miles (101 000 km)
ri er fl ui d.
66,000 Miles (106 000 km)
69,000 Miles (110 000 km)
72,000 Miles (115 000 km)
75,000 Miles (120 000 km)
necessary.
Replace spark plugs.
Replace ignition cables.
Drai n and refi l l automati c transaxl e fl ui d and
repl ace fi l ter. Adjust band, i f so equi pped. (See note)
78,000 Miles (125 000 km)
81,000 Miles (130 000 km)
84,000 Miles (134 000 km)
ri er fl ui d.
87,000 Miles (139 000 km)
90,000 Miles (144 000 km)
Check PCV valve and replace if necessary.
Not required if previously changed. *
note)
93,000 Miles (149 000 km)
96,000 Miles (154 000 km)
99,000 Miles (158 000 km)
102,000 Miles (163 000 km)
105,000 Miles (168 000 km)
necessary.
and fi l ter. Adjust bands, i f so equi pped. (See note)
ri er fl ui d.
108,000 Miles (173 000 km)
111,000 Miles (178 000 km)
114,000 Miles (182 000 km)
117,000 Miles (187 000 km)
120,000 Miles (192 000 km)
Inspect PCV valve. Replace as necessary. *
I nspect serpenti ne dri ve bel t. Not requi red i f
repl aced at 75,000, 90,000 or 105,000 mi l es.
and repl ace fi l ter. Adjust bands, i f so equi pped.
* Thi s mai ntenance i s recommended by Chrysl er to
the owner but i s not requi red to mai ntai n the war-
ranty on the PCV val ve.
** I f Cal i forni a vehi cl e, thi s mai ntenance i s recom-
mended by Chrysl er to the owner but i s not requi red
to mai ntai n the warranty of the ti mi ng bel t.
NOTE: Operating vehicle more than 50% in heavy
traffic during hot weather, above 90F (32C), using
vehicle for police, taxi, limousine type operation or
trailer towing require the more frequent transaxle
service noted in Schedule B. Perform these ser-
vices if vehicle is usually operated under these con-
ditions.
Inspection and service should also be performed
anytime a malfunction is observed or suspected.
J UMP STARTING, HOISTING AND TOWING
INDEX
page page
SERVICE PROCEDURES
HOISTING RECOMMENDATIONS . . . . . . . . . . . . 9
JUMP STARTING PROCEDURE . . . . . . . . . . . . . . 7
TOWING RECOMMENDATIONS . . . . . . . . . . . . . . 8
SERVICE PROCEDURES
JUMP STARTING PROCEDURE
WARNING: REVIEW ALL SAFETY PRECAUTIONS
AND WARNINGS IN GROUP 8A, BATTERY/START-
ING/CHARGING SYSTEMS DIAGNOSTICS. DO NOT
JUMP START A FROZEN BATTERY, PERSONAL
INJURY CAN RESULT. DO NOT JUMP START WHEN
MAINTENANCE FREE BATTERY INDICATOR DOT IS
YELLOW OR BRIGHT COLOR. DO NOT JUMP
START A VEHICLE WHEN THE BATTERY FLUID IS
BELOW THE TOP OF LEAD PLATES. DO NOT
ALLOW JUMPER CABLE CLAMPS TO TOUCH
EACH OTHER WHEN CONNECTED TO A BOOSTER
SOURCE. DO NOT USE OPEN FLAME NEAR BAT-
TERY. REMOVE METALLIC JEWELRY WORN ON
HANDS OR WRISTS TO AVOID INJURY BY ACCI-
DENTAL ARCING OF BATTERY CURRENT. WHEN
USING A HIGH OUTPUT BOOSTING DEVICE, DO
NOT ALLOW BATTERY VOLTAGE TO EXCEED 16
VOLTS. REFER TO INSTRUCTIONS PROVIDED
WITH DEVICE BEING USED.
CAUTION: When using another vehicle as a
booster, do not allow vehicles to touch. Electrical
systems can be damaged on either vehicle.
TO J UMP START A DISABLED VEHICLE:
(1) Rai se hood on di sabl ed vehi cl e and vi sual l y
i nspect engi ne compartment for:
Battery cabl e cl amp condi ti on, cl ean i f necessary.
Frozen battery.
Yel l ow or bri ght col or test i ndi cator, i f equi pped.
Low battery fl ui d l evel .
Generator dri ve bel t condi ti on and tensi on.
Fuel fumes or l eakage, correct i f necessary.
CAUTION: If the cause of starting problem on dis-
abled vehicle is severe, damage to booster vehicle
charging system can result.
(2) When usi ng another vehi cl e as a booster
source, park the booster vehi cl e wi thi n cabl e reach.
Turn off al l accessori es, set the parki ng brake, pl ace
the automati c transmi ssi on i n PARK or the manual
transmi ssi on i n NEUTRAL and turn the i gni ti on
OFF.
(3) On di sabl ed vehi cl e, pl ace gear sel ector i n park
or neutral and set park brake. Turn off al l accesso-
ri es.
(4) Connect jumper cabl es to booster battery. RED
cl amp to posi ti ve termi nal (+). BLACK cl amp to neg-
ati ve termi nal (-). DO NOT al l ow cl amps at opposi te
end of cabl es to touch, el ectri cal arc wi l l resul t.
Revi ew al l warni ngs i n thi s procedure.
(5) On di sabl ed vehi cl e, connect RED jumper cabl e
cl amp to posi ti ve (+) termi nal . Connect BLACK
jumper cabl e cl amp to engi ne ground as cl ose to the
ground cabl e attachi ng poi nt as possi bl e (Fi g. 1).
(6) Start the engi ne i n the vehi cl e whi ch has the
booster battery, l et the engi ne i dl e a few mi nutes,
then start the engi ne i n the vehi cl e wi th the di s-
charged battery.
CAUTION: Do not crank starter motor on disabled
vehicle for more than 15 seconds, starter will over-
heat and could fail.
(7) Al l ow battery i n di sabl ed vehi cl e to charge to
at l east 12.4 vol ts (75% charge) before attempti ng to
start engi ne. I f engi ne does not start wi thi n 15 sec-
onds, stop cranki ng engi ne and al l ow starter to cool
(15 mi n.), before cranki ng agai n.
Fig. 1 Jumper Cable Clamp Connections
DISCONNECT CABLE CLAMPS AS FOLLOWS:
Di sconnect BLACK cabl e cl amp from engi ne
ground on di sabl ed vehi cl e.
When usi ng a Booster vehi cl e, di sconnect
BLACK cabl e cl amp from battery negati ve termi nal .
Di sconnect RED cabl e cl amp from battery posi ti ve
termi nal .
Di sconnect RED cabl e cl amp from battery posi -
ti ve termi nal on di sabl ed vehi cl e.
TOWING RECOMMENDATIONS
WARNINGS AND CAUTIONS
WARNING: DO NOT ALLOW TOWING ATTACH-
MENT DEVICES TO CONTACT THE FUEL TANK OR
LINES, FUEL LEAK CAN RESULT.
DO NOT LIFT OR TOW VEHICLE BY FRONT OR
REAR BUMPER, OR BUMPER ENERGY ABSORBER
UNITS.
DO NOT GO UNDER A LIFTED VEHICLE IF NOT
SUPPORTED PROPERLY ON SAFETY STANDS.
DO NOT ALLOW PASSENGERS TO RIDE IN A
TOWED VEHICLE.
USE A SAFETY CHAIN THAT IS INDEPENDENT
FROM THE TOWING ATTACHMENT DEVICE.
CAUTION: Do not damage brake lines, exhaust sys-
tem, shock absorbers, sway bars, or any other
under vehicle components when attaching towing
device to vehicle.
Do not attach towing device to front or rear sus-
pension components.
Do not secure vehicle to towing device by the use
of front or rear suspension or steering components.
Remove or secure loose or protruding objects
from a damaged vehicle before towing.
Refer to state and local rules and regulations
before towing a vehicle.
Do not allow weight of towed vehicle to bear on
lower fascia, air dams, or spoilers.
RECOMMENDED TOWING EQUIPMENT
To avoi d damage to bumper fasci a and ai r dams
use of a fl at bed towi ng devi ce or wheel l i ft (Fi g. 2) i s
recommended. When usi ng a wheel l i ft towi ng devi ce,
be sure the di sabl ed vehi cl e has at l east 100 mm (4
i n.) ground cl earance. I f mi ni mum ground cl earance
cannot be reached, use a towi ng dol l y. I f a fl at bed
devi ce i s used, the approach angl e shoul d not exceed
15 degrees.
GROUND CLEARANCE
CAUTION: If vehicle is towed with wheels
removed, install lug nuts to retain brake drums or
rotors.
A towed vehi cl e shoul d be rai sed unti l the l i fted
wheel s are a mi ni mum 100 mm (4 i n.) from the
ground. Be sure there i s at l east 100 mm (4 i n.)
cl earance between the tai l pi pe and the ground. I f
necessary, remove the wheel s from the l i fted end of
the vehi cl e and l ower the vehi cl e cl oser to the
ground, to i ncrease the ground cl earance at the rear
of the vehi cl e. I nstal l l ug nuts on wheel attachi ng
studs to retai n brake drums or rotors.
LOCKED VEHICLE TOWING
When a l ocked vehi cl e must be towed wi th the
front wheel s on the ground, use a towi ng dol l y or fl at
bed haul er.
FLAT TOWING WITH TOW BAR
3-speed automati c transaxl e vehi cl es can be fl at
towed at speeds not to exceed 40 km/h (25 mph) for
not more than 25 km (15 mi l es). The steeri ng col umn
must be unl ocked and gear sel ector i n neutral .
4-speed el ectroni c automati c transaxl e vehi cl es
can be fl at towed at speeds not to exceed 72 km/h (44
mph) for not more than 160 km (100 mi l es). The
steeri ng col umn must be unl ocked and gear sel ector
i n neutral .
FLAT BED TOWING TIE DOWNS
CAUTION: Do not tie vehicle down by attaching
chains or cables to suspension components or
engine mounts, damage to vehicle can result.
NS vehi cl es can be ti ed to a fl at bed devi ce usi ng
the rei nforced l oops l ocated under the front and rear
bumpers on the dri vers si de of the vehi cl e. There are
al so four rei nforced el ongated hol es for T or R-hooks
l ocated on the bottom of the front frame rai l torque
Fig. 2 Recommended Towing Devices
SERVICE PROCEDURES (Continued)
boxes behi nd the front wheel s and forward of the
rear wheel s i nboard of the rocker panel wel d seam.
TOWINGFRONT WHEEL LIFT
Chrysl er Corporati on recommends that a vehi cl e be
towed wi th the front end l i fted, whenever possi bl e. A
90 cm (36 i n.) l ength of 4x4 wood beam can be pl aced
between the wheel l i ft devi ce and the bottom of the
fasci a to prevent damage to vehi cl e duri ng the l i fti ng
operati on. The beam can removed after l i fti ng the
front of the vehi cl e.
TOWINGREAR WHEEL LIFT
I f a vehi cl e cannot be towed wi th the front wheel s
l i fted, the rear wheel s can be l i fted provi ded the fol -
l owi ng gui de l i nes are observed.
CAUTION: Do not use steering column lock to
secure steering wheel during towing operation.
On AWD vehi cl es, al l four wheel s must be free to
rotate. Use towi ng dol l i es at unl i fted end of vehi cl e.
Unl ock steeri ng col umn and secure steeri ng
wheel i n strai ght ahead posi ti on wi th a cl amp devi ce
desi gned for towi ng.
3-speed automati c transaxl e vehi cl es can be fl at
towed at speeds not to exceed 40 km/h (25 mph) for
not more than 25 km (15 mi l es). The steeri ng col umn
must be unl ocked and gear sel ector i n neutral .
i n neutral .
HOISTING RECOMMENDATIONS
Refer to Owners Manual provi ded wi th vehi cl e for
proper emergency jacki ng procedures.
WARNING: THE HOISTING AND JACK LIFTING
POINTS PROVIDED ARE FOR A COMPLETE VEHI-
CLE. WHEN THE ENGINE OR REAR SUSPENSION
IS REMOVED FROM A VEHICLE, THE CENTER OF
GRAVITY IS ALTERED MAKING SOME HOISTING
CONDITIONS UNSTABLE. PROPERLY SUPPORT OR
SECURE VEHICLE TO HOISTING DEVICE WHEN
THESE CONDITIONS EXIST.
CAUTION: Do not position hoisting device on sus-
pension components or front crossmember, dam-
age to vehicle can result.
TO HOIST OR J ACK VEHICLE SEE (Fi g. 3).
Vehi cl es wi th factory i nstal l ed ground effects are
equi pped wi th front and rear hoi sti ng pads. These
pads are stamped, Hoi st Poi nt.
Fig. 3 HOISTING AND JACKING POINTS
LUBRICATION AND MAINTENANCE
CONTENTS
page page
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 1
JUMP STARTING, HOISTING AND TOWING . . . 5
MAINTENANCE SCHEDULES . . . . . . . . . . . . . . . 2
GENERAL INFORMATION
INDEX
page page
GENERAL INFORMATION
ENGINE OIL GASOLINE ENGINES . . . . . . . . 1
ENGINE OILDIESEL ENGINES . . . . . . . . . . . . 1
FLUID CAPACITIES . . . . . . . . . . . . . . . . . . . . . . 1
MANUAL TRANSMISSION FLUID
(A-558 and A-598 Models) . . . . . . . . . . . . . . . . 1
GENERAL INFORMATION
ENGINE OIL GASOLINE ENGINES
Use onl y oi l s conformi ng to API (Ameri can Petro-
l eum I nsti tute) Qual i ty SJ and Energy Conservi ng I I ,
or SH and Energy Conservi ng I I , or ACEA A196.
SAE VISCOSITY GRADE
To assure of properl y formul ated engi ne oi l s, i t i s
recommended that SAE Grade 5W-30 engi ne oi l s that
meet Chrysl er materi al standard MS-6395, be used.
SAE Grade 10W-30 oi l s are al so acceptabl e when the
temperatures do not fal l bel ow 0C. I n areas where
these grades are not general l y avai l abl e, hi gher SAE
grades may be used.
Lubri cants whi ch have both an SAE grade number
and the proper API servi ce cl assi fi cati on shown on
the contai ner shoul d be used.
ENGINE OIL DIESEL ENGINES
Use onl y Di esel Engi ne Oi l meeti ng standard MIL-
2104C or API Cl assi fi cati on SG/CD or CCMC PD2.
SAE VISCOSITY GRADE
CAUTION: Low viscosity oils must have the proper
API quality or the CCMC G5 designation.
To assure of properl y formul ated engi ne oi l s, i t i s recom-
mended that SAE Grade 15W-40 engi ne oi l s that meet
Chrysl er materi al standard MS-6395, be used. European
Grade 10W-40 oi l s are al so acceptabl e.
Oi l s of the SAE 5W-30 or 10W-30 grade number
are preferred when mi ni mum temperatures consi s-
tentl y fal l bel ow -12C.
MANUAL TRANSMISSION FLUID (A-558 and A-598
Models)
Use onl y SAE 10W-40 engi ne oi l s carryi ng the
European CCMC-G5 cl assi fi cati on to fi l l the A-598
5speed manual transmi ssi on.
FLUID CAPACITIES
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 L
2.0L Gasol i ne Engi ne Oi l wi th Fi l ter . . . . . . . . 4.3L
2.5L VM Di esel Engi ne Oi l Wi th Fi l ter . . . . . . 6.5 L
2.0L Gasol i ne Engi ne Cool i ng System* . . . . . . . 6.0L
2.5L VM Di esel Engi ne Cool i ng System* . . . . 10.0 L
Transmi ssi on5-Speed Manual . . . . . . . . . . . . 2.2 L
* I ncl udes heater and cool ant recovery tank fi l l ed
to Max l evel . Add 2.76L i f equi pped wi th Rear
Heater.
NS/GS LUBRICATION AND MAINTENANCE 0 - 1
MAINTENANCE SCHEDULES
INDEX
page page
GENERAL INFORMATION
MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . 2
MAINTENANCE SCHEDULE
DIESEL ENGINE . . . . . . . . . . . . . . . . . . . . . . . 2
SCHEDULEA (DIESEL) . . . . . . . . . . . . . . . . . . 2
SCHEDULEB (DIESEL) . . . . . . . . . . . . . . . . . . 3
UNSCHEDULED INSPECTION . . . . . . . . . . . . . . 2
GENERAL INFORMATION
MAINTENANCE SCHEDULE
Refer to the 1998 GS Servi ce Manual for Gasol i ne
Engi ne and non-engi ne rel ated Mai ntenance Sched-
ul es.
MAINTENANCE SCHEDULE DIESEL ENGINE
The fol l owi ng are engi ne rel ated Mai ntenance
i tems whi ch are uni que to Di esel engi ne-equi pped
vehi cl es. Refer to the 1998 GS Servi ce Manual for
Gasol i ne Engi ne and non-engi ne rel ated Mai ntenance
Schedul es.
The servi ce i nterval s are based on odometer read-
i ngs i n ki l ometers. There are two mai ntenance sched-
ul es that show proper servi ce i nterval s. Use the
schedul e that best descri bes the condi ti ons the vehi -
cl e i s operated under. Schedule-A l i sts al l the sched-
ul ed mai ntenance to be performed under normal
operati ng condi ti ons. Schedule-B i s the schedul e for
vehi cl es that are operated under one or more of the
fol l owi ng condi ti ons:
Day and ni ght temperatures are bel ow freezi ng.
Stop and go dri vi ng.
Long peri ods of engi ne i dl i ng.
Dri vi ng i n dusty condi ti ons.
Short tri ps of l ess than 5 mi l es.
Operati on at sustai ned hi gh speeds duri ng hot
weather above 32C (90F).
Taxi , pol i ce or del i very servi ce.
Trai l er towi ng.
UNSCHEDULED INSPECTION
At Each Stop for Fuel
Check engi ne oi l l evel , add as requi red.
Check wi ndshi el d washer sol vent and add i f
requi red.
Once a Month
Check ti re pressure and l ook for unusual wear
or damage.
I nspect battery and cl ean and ti ghten termi nal s
as requi red.
Check fl ui d l evel s of cool ant reservoi r, brake
master cyl i nder, power steeri ng and transaxl e and
add as needed.
Check al l l i ghts and al l other el ectri cal i tems for
correct operati on.
Check rubber seal s on each si de of the radi ator
for proper fi t.
At Each Oil Change
I nspect exhaust system.
I nspect brake hoses
I nspect the CV joi nts and front suspensi on com-
ponents
Rotate the ti res at each oi l change i nterval
shown on Schedul eA (7,500 mi l es) or every other
i nterval shown on Schedul e B (6,000 mi l es).
Check the cool ant l evel , hoses, and cl amps.
I f your mi l eage i s l ess than 7,500 mi l es (12 000
km) yearl y, repl ace the engi ne oi l fi l ter at each oi l
change.
SCHEDULE A (DIESEL)
1 000 KM
Change engi ne oi l fi l ter.
Check al l fl ui d l evel s.
Check correct torque, i ntake mani fol d mounti ng
nuts.
Check correct torque, exhaust mani fol d mount-
i ng nuts.
Check correct torque, turbocharger mounti ng
nuts.
Check correct torque, water mani fol d bol ts.
10 000 KM
20 000 KM
Repl ace ai r fi l ter el ement.
0 - 2 LUBRICATION AND MAINTENANCE NS/GS
Check dri ve bel t tensi on.
Check gl ow pl ug operati on.
30 000 KM
40 000 KM
Repl ace fuel fi l ter/water separator el ement.**
50 000 KM
60 000 KM
Repl ace dri ve bel t.
Check engi ne smoke.
Repl ace engi ne cool ant.
70 000 KM
80 000 KM
90 000 KM
100 000 KM
EVERY 40 000 KM AFTER 80 000 KM
**The fuel fi l ter/water separator el ement shoul d be
repl aced once a year i f the vehi cl e i s dri ven l ess than
40 000 km annual l y or i f power l oss from fuel star-
vati on i s detected.
SCHEDULE B (DIESEL)
500 KM
Check correct torque, i ntake mani fol d mounti ng
nuts.
Check correct torque, exhaust mani fol d mount-
i ng nuts.
Check correct torque, turbocharger mounti ng
nuts.
Check correct torque, water mani fol d bol ts.
1 000 KM
Check al l fl ui d l evel s.
5 000 KM
10 000 KM
15 000 KM
20 000 KM
25 000 KM
30 000 KM
35 000 KM
Change MTX Fl ui d
40 000 KM
Di esel engi nes onl yRepl ace fuel fi l ter/water
separator el ement.
45 000 KM
50 000 KM
55 000 KM
60 000 KM
separator el ement.
65 000 KM
70 000 KM
Change MTX fl ui d
75 000 KM
80 000 KM
85 000 KM
90 000 KM
95 000 KM
100 000 KM
separator el ement.
Change MTX fl ui d
separator el ement.
Change MTX fl ui d
J UMP STARTING, HOISTING AND TOWING
INDEX
page
SERVICE PROCEDURES
TOWING RECOMMENDATIONS . . . . . . . . . . . . . 5
SERVICE PROCEDURES
TOWING RECOMMENDATIONS
WARNINGS AND CAUTIONS
WARNING: DO NOT ALLOW TOWING ATTACH-
MENT DEVICES TO CONTACT THE FUEL TANK OR
LINES, FUEL LEAK CAN RESULT.
DO NOT LIFT OR TOW VEHICLE BY FRONT OR
REAR BUMPER, OR BUMPER ENERGY ABSORBER
UNITS.
DO NOT GO UNDER A LIFTED VEHICLE IF NOT
SUPPORTED PROPERLY ON SAFETY STANDS.
DO NOT ALLOW PASSENGERS TO RIDE IN A
TOWED VEHICLE.
USE A SAFETY CHAIN THAT IS INDEPENDENT
FROM THE TOWING ATTACHMENT DEVICE.
CAUTION: Do not damage brake lines, exhaust sys-
tem, shock absorbers, sway bars, or any other
under vehicle components when attaching towing
device to vehicle.
Do not attach towing device to front or rear sus-
pension components.
Do not secure vehicle to towing device by the use
of front or rear suspension or steering components.
Remove or secure loose or protruding objects
from a damaged vehicle before towing.
Refer to state and local rules and regulations
before towing a vehicle.
Do not allow weight of towed vehicle to bear on
lower fascia, air dams, or spoilers.
RECOMMENDED TOWING EQUIPMENT
To avoi d damage to bumper fasci a and ai r dams
use of a fl at bed towi ng devi ce or wheel l i ft (Fi g. 1) i s
recommended. When usi ng a wheel l i ft towi ng devi ce,
be sure the di sabl ed vehi cl e has at l east 100 mm (4
i n.) ground cl earance. I f mi ni mum ground cl earance
cannot be reached, use a towi ng dol l y. I f a fl at bed
devi ce i s used, the approach angl e shoul d not exceed
15 degrees.
GROUND CLEARANCE
CAUTION: If vehicle is towed with wheels
removed, install lug nuts to retain brake drums or
rotors.
A towed vehi cl e shoul d be rai sed unti l the l i fted
wheel s are a mi ni mum 100 mm (4 i n.) from the
ground. Be sure there i s at l east 100 mm (4 i n.)
cl earance between the tai l pi pe and the ground. I f
necessary, remove the wheel s from the l i fted end of
the vehi cl e and l ower the vehi cl e cl oser to the
ground, to i ncrease the ground cl earance at the rear
of the vehi cl e. I nstal l l ug nuts on wheel attachi ng
studs to retai n brake drums or rotors.
LOCKED VEHICLE TOWING
When a l ocked vehi cl e must be towed wi th the
front wheel s on the ground, use a towi ng dol l y or fl at
bed haul er.
FLAT TOWING WITH TOW BAR
i n neutral .
FLAT BED TOWING TIE DOWNS
CAUTION: Do not tie vehicle down by attaching
chains or cables to suspension components or
engine mounts, damage to vehicle can result.
Fig. 1 Recommended Towing Devices
NS vehi cl es can be ti ed to a fl at bed devi ce usi ng
the rei nforced l oops l ocated under the front and rear
bumpers on the dri vers si de of the vehi cl e. There are
al so four rei nforced el ongated hol es for T or R-hooks
l ocated on the bottom of the front frame rai l torque
boxes behi nd the front wheel s and forward of the
rear wheel s i nboard of the rocker panel wel d seam.
TOWINGFRONT WHEEL LIFT
Chrysl er I nternati onal recommends that a vehi cl e
be towed wi th the front end l i fted, whenever possi bl e.
A 90 cm (36 i n.) l ength of 4x4 wood beam can be
pl aced between the wheel l i ft devi ce and the bottom
of the fasci a to prevent damage to vehi cl e duri ng the
l i fti ng operati on. The beam can removed after l i fti ng
the front of the vehi cl e.
TOWINGREAR WHEEL LIFT
I f a vehi cl e cannot be towed wi th the front wheel s
l i fted, the rear wheel s can be l i fted provi ded the fol -
l owi ng gui de l i nes are observed.
CAUTION: Do not use steering column lock to
secure steering wheel during towing operation.
On AWD vehi cl es, al l four wheel s must be free to
rotate. Use towi ng dol l i es at unl i fted end of vehi cl e.
Unl ock steeri ng col umn and secure steeri ng
wheel i n strai ght ahead posi ti on wi th a cl amp devi ce
desi gned for towi ng.
i n neutral .
TOWINGTOW HOOKS
WARNING: Do not use the tow hook to lift the vehi-
cle off the ground.
A tow-hook bol t, l ocated i n the rear i nteri or tri m
storage compartment (wi th jack), i s provi ded wi th
your vehi cl e. The tow hook i s used for towi ng the
vehi cl e wi th al l four wheel s on the ground onl y. I t
can be attached to the vehi cl e through an openi ng i n
the l ower front fasci a. The tow hook must be ful l y
seated to the attach bracket through the l ower front
fasci a as shown. I f the tow hook i s not ful l y seated to
the attach bracket the vehi cl e shoul d not be towed.
NOTE: The tow hook bolt protective plug must be
removed from the tow hook bracket prior to bolt
attachment. The tow hook is used ONLY for towing
the vehicle with all four wheels on the ground.
Fig. 2
SUSPENSION
CONTENTS
page page
FRONT SUSPENSION . . . . . . . . . . . . . . . . . . . . . . 9
REAR SUSPENSION . . . . . . . . . . . . . . . . . . . . . . 38
WHEEL ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . 1
WHEEL ALIGNMENT
INDEX
page page
DESCRIPTION AND OPERATION
DIAGNOSIS AND TESTING
PRE-WHEEL ALIGNMENT INSPECTION . . . . . . . 4
SUSPENSION AND STEERING DIAGNOSIS . . . . 3
SERVICE PROCEDURES
WHEEL ALIGNMENT CHECK AND
ADJUSTMENT PROCEDURE . . . . . . . . . . . . . . 4
SPECIFICATIONS
ALIGNMENT SPECIFICATIONS . . . . . . . . . . . . . . 7
GENERAL INFORMATION
Wheel al i gnment i s the proper adjustment of al l
the i nterrel ated suspensi on angl es affecti ng the run-
ni ng and steeri ng of the front and rear wheel s of the
vehi cl e.
The method of checki ng front and rear wheel al i gn-
ment wi l l vary dependi ng on the type of equi pment
bei ng used. The i nstructi ons furni shed by the manu-
facturer of the equi pment shoul d al ways be fol l owed.
Wi th the excepti on that the wheel al i gnment speci fi -
cati ons recommended by Chrysl er Corporati on shoul d
al ways be used. The Chrysl er Corporati on recom-
mended al i gnment speci fi cati ons, are l i sted i n Speci -
fi cati ons at the end of thi s group i n the servi ce
manual secti on.
There are si x basi c factors whi ch are the founda-
ti on to front wheel al i gnment. These are vehi cl e
hei ght, caster, camber, toe-i n, steeri ng axi s i ncl i na-
ti on and toe-out on turns. Of the si x basi c factors
onl y toe-i n i s normal l y mechani cal l y adjustabl e on
thi s vehi cl e (Fi g. 1).
NS SUSPENSION 2 - 1
Camber adjustment i s al l owed i n the event that a
vehi cl e i s i nvol ved i n an acci dent and after repai rs
are made meeti ng manufacturers tol erance speci fi ca-
ti ons, the camber setti ng wi l l not meet manufactur-
ers speci fi cati ons. I f camber adjustment i s requi red,
refer to the fol l owi ng Servi ce Camber Adjustment
Procedure for the requi red steps to be fol l owed.
CAUTION: Do not attempt to modify any suspen-
sion or steering components to meet vehicle align-
ment specifications, by heating and or bending.
Al i gnment checks and adjustments shoul d be made
i n the fol l owi ng sequence.
(1) Camber
(2) Toe
Camber i s the number of degrees the top of the
wheel and ti re assembl y i s ti l ted i nboard or outboard
from a true verti cal l i ne. I nboard ti l t i s negati ve cam-
ber. Outboard ti l t i s posi ti ve camber (Fi g. 1).
Excessi ve camber i s a ti re wear factor: negati ve
camber causes wear on the i nsi de of the ti res tread
surface, whi l e posi ti ve camber causes wear to the
outsi de of the ti res tread surface. See Front Wheel
Dri ve Speci fi cati ons for Camber. setti ngs.
Toe i s measured i n degrees or i nches and i s the
di stance the front edges of the ti res are cl oser (or far-
ther apart) than the rear edges. See Front Wheel
Dri ve Speci fi cati ons for Toe. setti ngs.
Fig. 1 Front Suspension Alignment Angles
2 - 2 SUSPENSION NS
DESCRIPTION AND OPERATION (Continued)
SUSPENSION AND STEERING DIAGNOSIS
CONDITION POSSIBLE CAUSES CORRECTION
Front End Whine On Turns 1. Defective wheel bearing 1. Replace wheel bearing
2. Incorrect wheel alignment 2. Check and reset wheel alignment
3. Worn tires 3. Replace tires
Front End Growl Or Grinding On
Turns
1. Defective wheel bearing 1. Replace wheel bearing
2. Engine mount grounding 2. Check for motor mount hitting
frame rail and reposition engine as
required
3. Worn or broken C/V joint 3. Replace C/V joint
4. Loose wheel lug nuts 4. Verify wheel lug nut torque
7. Front strut pin in upper strut mount 7. Replace the front strut upper mount
and bearing
Front End Clunk Or Snap On Turns 1. Loose lug nuts 1. Verify wheel lug nut torque
3. Worn or loose tie rod 3. Tighten or replace tie rod end
4. Worn or loose ball joint 4. Tighten or replace ball joint
5. Worn/loose control arm bushing 5. Replace control arm bushing
6. Loose stabilizer bar. 6. Tighten stabilizer bar to specified
torque
7. Loose strut mount to body
attachment
7. Tighten strut attachment to
specified torque
8. Loose crossmember bolts 8. Tighten crossmember bolts to
specified torque
Front End Whine With Vehicle
Going Straight At A Constant Speed
1. Defective wheel bearing 1. Replace wheel bearing
4. Worn or defective transaxle gears
or bearings
4. Replace transaxle gears or
bearings
Front End Growl Or Grinding With
Vehicle Going Straight At A
Constant Speed
1. Engine mount grounding 1. Reposition engine as required
Front End Whine When
Accelerating Or Decelerating
or bearings
bearings
Front End Clunk When Accelerating
Or Decelerating
1. Worn or broken engine mount 1. Replace engine mount
or bearings
bearings
3. Loose lug nuts 3. Verify wheel lug nut torque
5. Worn or loose ball joint 5. Tighten or replace ball joint
6. Worn or loose control arm bushing 6. Replace control arm bushing
7. Loose crossmember bolts 7. Tighten crossmember bolts to
specified torque
8. Worn tie rod end 8. Replace tie rod end
NS SUSPENSION 2 - 3
Road Wander 1. Incorrect tire pressure 1. Inflate tires to recommended
pressure
2. Incorrect front or rear wheel toe 2. Check and reset wheel toe
3. Worn wheel bearings 3. Replace wheel bearing
4. Worn control arm bushings 4. Replace control arm bushing
5. Excessive friction in steering gear 5. Replace steering gear
6. Excessive friction in steering shaft
coupling
6. Replace steering coupler
7. Excessive friction in strut upper
bearing
7. Replace strut bearing
Lateral Pull 1. Unequal tire pressure 1. Inflate all tires to recommended
pressure
2. Radial tire lead 2. Perform lead correction procedure
3. Incorrect front wheel camber 3. Check and reset front wheel
camber
4. Power steering gear imbalance 4. Replace power steering gear
5. Wheel braking 5. Correct braking condition causing
lateral pull
Excessive Steering Free Play 1. Incorrect Steering Gear Adjustment 1. Adjust Or Replace Steering Gear
2. Worn or loose tie rod ends 2. Replace or tighten tie rod ends
3. Loose steering gear mounting bolts 3. Tighten steering gear bolts to
specified torque
4. Loose or worn steering shaft
coupler
4. Replace steering shaft coupler
Excessive Steering Effort 1. Low tire pressure 1. Inflate all tires to recommended
pressure
2. Lack of lubricant in steering gear 2. Replace steering gear
3. Low power steering fluid level 3. Fill power steering fluid reservoir to
correct level
4. Loose power steering pump drive
belt
4. Correctly adjust power steering
pump drive belt
5. Lack of lubricant in ball joints 5. Lubricate or replace ball joints
6. Steering gear malfunction 6. Replace steering gear
7. Lack of lubricant in steering
coupler
7. Replace steering coupler
PRE-WHEEL ALIGNMENT INSPECTION
Before any attempt i s made to change or correct
the wheel al i gnment factors. The fol l owi ng part
i nspecti on and the necessary correcti ons shoul d be
made to those parts whi ch i nfl uence the steeri ng of
the vehi cl e.
(1) Check and i nfl ate al l ti res to recommended
pressure. Al l ti res shoul d be the same si ze and i n
good condi ti on and have approxi matel y the same
wear. Note the type of tread wear whi ch wi l l ai d i n
di agnosi ng, see Wheel s and Ti res, Group 22.
(2) Check front wheel and ti re assembl y for radi al
runout.
(3) I nspect l ower bal l joi nts and al l steeri ng l i nk-
age for l ooseness.
(4) Check for broken or sagged front and rear
spri ngs.
(5) Check vehi cl e ri de hei ght to veri fy i t i s wi thi n
speci fi cati ons.
(6) Al i gnment MUST onl y be checked after the
vehi cl e has the fol l owi ng areas i nspected and or
adjusted. Recommended ti re pressures, ful l tank of
fuel , no passenger or l uggage compartment l oad and
i s on a l evel fl oor or a properl y cal i brated al i gnment
rack.
SERVICE PROCEDURES
WHEEL ALIGNMENT CHECK AND ADJUSTMENT
PROCEDURE
CASTER AND CAMBER
Front suspensi on Caster and Camber setti ngs on
thi s vehi cl e are determi ned at the ti me the vehi cl e i s
desi gned. Thi s i s done by determi ni ng the preci se
2 - 4 SUSPENSION NS
DIAGNOSIS AND TESTING (Continued)
mounti ng l ocati on of the vehi cl es suspensi on compo-
nents throughout the desi gn and assembl y processes
of the vehi cl e. Thi s i s cal l ed a Net Bui l d vehi cl e and
resul ts i n no normal requi rement to adjustment the
Caster and Camber after a vehi cl e i s bui l t or when
servi ci ng the suspensi on components. Thus Caster
and Camber are not normal l y consi dered an adjust-
abl e speci fi cati on when performi ng an al i gnment on
thi s vehi cl e. Though Caster and Camber are not
adjustabl e they shoul d be checked duri ng the al i gn-
ment procedure to ensure they meet the manufactur-
ers speci fi cati ons.
I f front camber does not meet the vehi cl e al i gn-
ment speci fi cati ons, i t can be adjusted usi ng a Mopar
Servi ce Ki t devel oped to al l ow for camber adjust-
ment. I f a vehi cl es front camber does not meet
requi red speci fi cati ons, the vehi cl es suspensi on com-
ponents shoul d be i nspected for any si gns of damage
or bendi ng and the vehi cl e ri de hei ght shoul d be
checked to veri fy i t i s wi thi n requi red speci fi cati on.
This inspection must be done before using the
Mopar Service Kit for setting camber to the
vehicle specification.
CAUTION: Do not attempt to adjust the vehicles
Caster or Camber by heating, bending or by per-
forming any other modification to the vehicles front
suspension components.
(1) Correctl y posi ti on the vehi cl e on the al i gnment
rack. Then i nstal l al l requi red al i gnment equi pment
on the vehi cl e, per the al i gnment equi pment manu-
facturers speci fi cati ons.
NOTE: Prior to reading each alignment specifica-
tion, front and rear of vehicle should be jounced an
equal number of times. Induce jounce (rear first
then front) by grasping center of bumper and jounc-
ing each end of vehicle an equal number of times.
Bumper should always be released when vehicle is
at the bottom of the jounce cycle.
(2) Correctl y jounce vehi cl e and then read the
vehi cl es current front and rear al i gnment setti ngs.
Compare the vehi cl es current al i gnment setti ngs to
the vehi cl e speci fi cati ons for camber, caster and Toe-
i n. See Al i gnment Speci fi cati ons i n thi s group of the
servi ce manual for the requi red speci fi cati ons. If
front and rear camber readings are within
required specifications proceed to step Step 3
for the Toe-in adjustment procedure if
required. If Camber readings are not within
specifications refer to step Step 1 in the front
camber adjustment cam bolt adjustment proce-
dure.
CAMBER ADJUSTMENT CAM BOLT PACKAGE INSTALLATION
PROCEDURE
(1) I f the front camber readi ngs obtai ned are not
wi thi n the vehi cl es speci fi cati ons, use the fol l owi ng
procedure and the Mopar Cl evi s Bol t Servi ce Ki t to
provi de camber adjustment. The ki t contai ns 2 fl ange
bol ts, 2 cam bol ts, and 2 dog bone washers. These
components of the servi ce ki t are necessary to assem-
bl e the strut to the steeri ng knuckl e, after modi fi ca-
ti on of the strut cl evi s bracket.
(2) Veri fy that the strut and steeri ng knuckl e are
not bent or otherwi se damaged. I f ei ther component
i s bent or show other si gns of damage, repl ace
requi red component(s) and check the camber setti ng
agai n. Refer to Strut Damper Assembl y Servi ce i n
thi s group of the servi ce manual for the requi red
strut repl acement procedure.
(3) I f no component i s bent or damaged, use the
fol l owi ng procedure for modi fyi ng the strut cl evi s
bracket and adjusti ng the camber setti ng.
(4) Rai se front of vehi cl e unti l ti res are not sup-
porti ng the wei ght of the vehi cl e. Then remove wheel
and ti re assembl y from the l ocati on on the vehi cl e
requi ri ng the strut to be modi fi ed.
CAUTION: When removing the steering knuckle
from the strut clevis bracket, do not put a strain on
the brake flex hose. Also, do not let the weight of
the steering knuckle assembly be supported by the
brake flex hose when removed from the strut
assembly. If necessary use a wire hanger to sup-
port the steering knuckle assembly or if required
remove the brake flex hose from the caliper assem-
bly.
CAUTION: The steering knuckle strut assembly
attaching bolts are serrated and must not be turned
during removal. Remove nuts while holding bolts
stationary in the steering knuckles.
(5) Remove the top and bottom, strut cl evi s
bracket to steeri ng knuckl e attachi ng bol ts (Fi g. 2)
and di scard. Separate the steeri ng knuckl e from the
strut cl evi s bracket and posi ti on steeri ng knuckl e so
i t i s out of the way of the strut.
CAUTION: When slotting the bottom mounting
hole on the strut clevis bracket, do not enlarge the
hole beyond the indentations (Fig. 3) on the sides
of the strut clevis bracket.
NS SUSPENSION 2 - 5
(6) Usi ng an appropri ate gri nder and gri ndi ng
wheel sl ot the bottom hol e (Fi g. 3) i n both si des of
the strut cl evi s bracket. When grinding slot do not
go beyond the indentation area on the sides of
the clevis bracket (Fig. 3).
CAUTION: After slotting the strut clevis bracket
hole, do not install the original attaching bolts when
assembling the steering knuckle to the strut assem-
bly. Only the flange bolts, cam bolts, and dog bone
washers from the Mopar Clevis Bolt Service Kit, can
be used to attach the steering knuckle to the strut
after the mounting hole is slotted.
(7) I nstal l the fl anged bol t (Fi g. 4) from the Mopar
Cl evi s Bol t Servi ce Ki t, i nto the top cl evi s bracket to
steeri ng knuckl e mounti ng hol e. I nstal l the cam bol t
(Fi g. 4) i nto the bottom cl evi s bracket to steeri ng
knuckl e mounti ng hol e.
(8) I nstal l the dog bone washer (Fi g. 5) on the
steeri ng knuckl e to strut cl evi s bracket attachi ng
bol ts. Then i nstal l the nuts from the ori gi nal attach-
i ng bol ts onto the repl acement bol ts from the servi ce
ki t. Ti ghten the bol ts just enough to hol d the steeri ng
knuckl e i n posi ti on when adjusti ng camber, whi l e
sti l l al l owi ng the steeri ng knuckl e to move i n cl evi s
bracket.
(9) Lower vehi cl e unti l the ful l wei ght of the vehi -
cl e i s supported by the vehi cl es suspensi on. Then
correctl y jounce the front and rear of vehi cl e an equal
amount of ti mes.
(10) Adjust the front camber to the preferred set-
ti ng by rotati ng the l ower eccentri c cam bol t (Fi g. 6)
agai nst the cam stop areas on the strut cl evi s
bracket. When camber i s correctl y set, ti ghten the
upper strut cl evi s bracket bol t and l ower cam bol t.
Agai n jounce front and rear of vehi cl e an equal
amount of ti mes and veri fy front camber setti ng. See
Al i gnment Speci fi cati ons i n thi s group of the servi ce
manual for requi red speci fi cati ons.
Fig. 2 Clevis Bracket To Steering Knuckle Attaching
Bolts
Fig. 3 Strut Clevis Bracket Bolt Hole Grinding Area
Fig. 4 Mopar Service Kit Bolts Correctly Installed
Fig. 5 Dog Bone Washer And Nuts Installed On
Attaching Bolts
2 - 6 SUSPENSION NS
(11) When vehi cl e i s at correct camber setti ng
torque both front strut to steeri ng knuckl e attachi ng
bol ts to 90 Nm (65 ft. l bs.) pl us an addi ti onal 1/4
turn after requi red torque i s met.
(12) I f Toe readi ngs obtai ned are not wi thi n the
requi red speci fi cati on range, adjust Toe to meet the
preferred speci fi cati on setti ng. Toe i s adjustabl e
usi ng the fol l owi ng Toe setti ng procedure.
FRONT TOE SETTING PROCEDURE
(1) Prepare vehi cl e as descri bed i n the Pre-Al i gn-
ment Vehi cl e I nspecti on procedure.
(2) Center steeri ng wheel and l ock i n pl ace usi ng a
steeri ng wheel cl amp.
CAUTION: Do not twist front inner tie rod to steer-
ing gear rubber boots during front wheel Toe
adjustment.
(3) Loosen front i nner to outer ti e rod end jam
nuts (Fi g. 7). Grasp i nner ti e rods at serrati ons and
rotate i nner ti e rods of steeri ng gear (Fi g. 7) to set
front Toe to the preferred Toe speci fi cati on. See
Al i gnment Speci fi cati ons i n thi s group of the servi ce
manual for preferred speci fi cati on.
(4) Ti ghten ti e rod jam nuts (Fi g. 7) to 75 Nm (55
ft.l bs.) torque.
(5) Adjust steeri ng gear to ti e rod boots at ti e rod.
(6) Remove steeri ng wheel cl amp.
SPECIFICATIONS
ALIGNMENT SPECIFICATIONS
Al l al i gnment speci fi cati ons are to be checked and
adjusted wi th the vehi cl e at i ts correct ri de hei ght.
Refer to the ri de hei ght speci fi cati ons l i sted i n the
fol l owi ng al i gnment speci fi cati ons chart.
Fig. 6 Camber Adjustment Cam Bolt
Fig. 7 Front Wheel Toe Adjustment
NS SUSPENSION 2 - 7
* Camber is adjustable using the Mopar Camber Adjustment Service Kit. Refer to the Mopar
Parts Catalog for the required service kit part number.
** Caster is not adjustable. If found to be out of specification check for proper ride heights and
damaged/worn out suspension components and replace as necessary.
*** Toe-In is positive.
**** Toe, Camber and thrust angle are not adjustable. If found to be out of specification check for
proper ride heights and damaged/worn out suspension components and replace as necessary.
***** When Measuring ride heights: 1) Ensure that the tire pressures are correct. 2) J ounce the vehicle at the
bumper several times and release at the bottom of the stroke. 3) Measure from the ground to the outboard, lower,
center section of the fender wheel well opening. Ride heights are not adjustable. If found to be out of specification
check for damaged and/or worn out suspension components and replace as necessary.
ALIGNMENT ANGLE TIRE SIZES TIRE SIZES ALTERNATIVE FUELS
P205/75/R14 P205/75/R15 C.N.G.
P215/65/R15 P215/65/R16 ELECTRIC
* FRONT INDIVIDUAL CAMBER IN
DEGREES............................................
+0.15+or- 0.40 +0.05+or- 0.40 +0.15+or- 0.40
Front Side To Side Camber
Difference Not To Exceed...................
0.00- 0.50MAX 0.00- 0.50MAX 0.00- 0.50MAX
** FRONT INDIVIDUAL CASTER IN
DEGREES............................................
+1.40+ or - 1.00 +1.40+ or - 1.00 +1.40+or- 1.00
Front Side To Side Caster Difference
Not To
Exceed.....................................
0.00- 1.00MAX 0.00- 1.00MAX 0.00- 1.00MAX
*** FRONT INDIVIDUAL TOE
RIGHT/
LEFT.........................................
+0.05+or- 0.10 +0.05+or- 0.10 +0.05+or- 0.10
FRONT TOTAL
TOE....................................................
Specified In Degrees
+0.10+or- 0.20 +0.10+or- 0.20 +0.10+or- 0.20
FRONT SIDE TO SIDE TOE
DIFFERENTIAL.....................................
0.00- 0.06MAX 0.00- 0.06MAX 0.00- 0.06MAX
****REAR INDIVIDUAL CAMBER IN
DEGREES............................................
+0.00+or- 0.25 +0.00+or- 0.25 -0.10+or- 0.25
REAR INDIVIDUAL TOE RIGHT/
LEFT........................................
0.00+or- 0.40 0.00+or- 0.40 0.00+or- 0.40
**** REAR TOTAL TOE.....................
TOE OUT: When Backed On
Alignment Rack Is TOE In When
Driving
0.00+or- 0.40 0.00+or- 0.40 0.00+or- 0.40
****REAR THRUST ANGLE................ 0.00+or- 0.30 0.00+or- 0.30 0.00+or- 0.30
STEERING WHEEL
ANGLE................
0.00+or- 2.50 0.00+or- 2.50 0.00+or- 2.50
FRONT RIDE HEIGHT (MEASURED
AT TOP OF FENDER WHEEL
OPENING)............................................
747.5 mm +or-10.0mm 753.5 mm +or-10.0mm 783.5 mm +or-10.0mm
FRONT RIDE HEIGHT SIDE TO
SIDE
DIFFERENTIAL.....................................
0.0 mm 12.5 mm MAX 0.0 mm 12.5 mm MAX 0.0 mm 12.5 mm MAX
*****REAR RIDE HEIGHT
(MEASURED AT TOP OF FENDER
WHEEL
OPENING)............................................
766.0 mm +or-10.0mm 772.0 mm +or-10.0mm 802.5 mm +or-10.0mm
*****REAR RIDE HEIGHT SIDE TO
SIDE
DIFFERENTIAL.....................................
0.0 mm 12.5 mm MAX 0.0 mm 12.5 mm MAX 0.0 mm 12.5 mm MAX
2 - 8 SUSPENSION NS
SPECIFICATIONS (Continued)
FRONT SUSPENSION
INDEX
page page
BALL JOINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
COIL SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
FRONT SUSPENSION DESCRIPTION . . . . . . . . . 9
HUB AND BEARING ASSEMBLY . . . . . . . . . . . . 10
LOWER CONTROL ARM . . . . . . . . . . . . . . . . . . 10
Mc PHERSON STRUT ASSEMBLY . . . . . . . . . . . 10
STABILIZER BAR ATTACHING LINK . . . . . . . . . . 10
STABILIZER BAR . . . . . . . . . . . . . . . . . . . . . . . . 10
STEERING KNUCKLE . . . . . . . . . . . . . . . . . . . . 10
SUSPENSION CRADLE (CROSSMEMBER) . . . . . 9
WHEEL MOUNTING STUDS . . . . . . . . . . . . . . . . 11
BALL JOINT (LOWER) . . . . . . . . . . . . . . . . . . . . 12
Mc PHERSON STRUT . . . . . . . . . . . . . . . . . . . . 11
STABILIZER BAR . . . . . . . . . . . . . . . . . . . . . . . . 12
SERVICE PROCEDURES
SUSPENSION CRADLE THREAD REPAIR
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . 12
REMOVAL AND INSTALLATION
BALL JOINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
FRONT WHEEL MOUNTING STUDS . . . . . . . . . 28
Mc PHERSON STRUT . . . . . . . . . . . . . . . . . . . . 13
REAR WHEEL MOUNTING STUDS . . . . . . . . . . 29
STABILIZER BAR . . . . . . . . . . . . . . . . . . . . . . . . 23
DISASSEMBLY AND ASSEMBLY
BALL JOINT SEAL BOOT . . . . . . . . . . . . . . . . . . 33
LOWER CONTROL ARM FRONT BUSHING . . . . 34
LOWER CONTROL ARM REAR BUSHING . . . . . 35
Mc PHERSON STRUT . . . . . . . . . . . . . . . . . . . . 30
STABILIZER BAR BUSHING . . . . . . . . . . . . . . . . 35
SPECIFICATIONS
FRONT SUSPENSION FASTENER TORQUES . . 36
SPECIAL TOOLS
FRONT SUSPENSION . . . . . . . . . . . . . . . . . . . . 37
FRONT SUSPENSION DESCRIPTION
An i ndependent Mc Pherson Strut type front sus-
pensi on i s used on these vehi cl es. Verti cal shock
absorbi ng Mc Pherson Struts attach to the top of the
steeri ng knuckl e and to the front strut tower. Thi s
i nterconnecti on between the steeri ng knuckl e and the
body of the vehi cl e, provi des for the correct steeri ng
knuckl e posi ti on. Thi s steeri ng knuckl e posi ti on pro-
vi des for the correct front Caster and Camber set-
ti ngs for the vehi cl e, at the ti me the vehi cl e i s
desi gned.
Lower control arms are attached i nboard to the
cast al umi num front suspensi on cradl e and outboard
to the bottom of the steeri ng knuckl e. Attachment of
the l ower control arm to the steeri ng knuckl e i s done
through a bal l joi nt i n the l ower control arm.
Duri ng steeri ng maneuvers, the strut and the
steeri ng knuckl e (through the bal l joi nt and a pi vot
beari ng i n the struts upper retai ner) turn as an
assembl y.
SUSPENSION CRADLE (CROSSMEMBER)
Thi s vehi cl e uses a one pi ece cast al umi num cradl e
for the front suspensi on. The cradl e i s used as the
attachi ng poi nts for the l ower control arms, stabi l i zer
bar and steeri ng gear. The cradl e al so has the power
steeri ng hoses and the chassi s brake tubes attached
to i t.
The cradl e i s mounted to the front frame rai l s at
four poi nts, two on each si de of the vehi cl e. The cra-
dl e i s i sol ated from the body of the vehi cl e usi ng four
i sol ators, one l ocated at each mounti ng bol t l ocati on.
WARNING: If a threaded hole in the suspension
cradle needs to be repaired, only use the type of
thread insert and installation procedure specified
for this application.
The threaded holes in the cradle that are
used for attachment of the lower control arm
rear bushing retainer, power steering hose and
chassis brake tubes can be repaired. The repair
is done by the installation of a Heli-Coil
thread insert which has been specifically devel-
oped for this application. Refer to the Mopar
Parts Catalog for the specified Heli-Coil thread
insert to be used for this application. The pro-
cedure for installing the Heli-Coil thread
insert is detailed in the Service Procedures sec-
tion in this group of the service manual.
NS SUSPENSION 2 - 9
Mc PHERSON STRUT ASSEMBLY
The front suspensi on of the vehi cl e i s supported by
coi l spri ngs posi ti oned around the strut assembl y.
The spri ngs are contai ned between an upper seat,
l ocated just bel ow the top strut mount assembl y and
a l ower spri ng seat on the strut fl ui d reservoi r.
The top of each strut assembl y i s bol ted to the
upper fender rei nforcement (strut tower) through a
rubber i sol ated mount.
The bottom of the strut assembl y attaches to the
steeri ng knuckl e wi th two through bol ts. Caster i s a
fi xed setti ng on al l vehi cl es and i s not adjustabl e
when an al i gnment i s performed. I n the event the
camber setti ng on a vehi cl e requi res adjustment, a
servi ce strut i s avai l abl e whi ch wi l l provi de a method
by whi ch the camber can be adjusted.
The strut assembl i es on thi s vehi cl e are i nter-con-
nected by the front stabi l i zer bar through 2 l i nk
assembl i es attachi ng the struts to the stabi l i zer bar.
STEERING KNUCKLE
The steeri ng knuckl e (Fi g. 1) i s a si ngl e casti ng
wi th l egs machi ned for attachment of the strut
damper, steeri ng l i nkage, di sc brake cal i per, and
l ower control arm bal l joi nt. The steeri ng knuckl e
al so has the front hub/beari ng assembl y mounted to
i t. The hub i s posi ti oned through the beari ng and
knuckl e, wi th the constant vel oci ty stub shaft spl i ned
through the hub.
LOWER CONTROL ARM
The l ower control arm i s an i ron casti ng. The l ower
control arm i s mounted to and i sol ated from the body
of the vehi cl e usi ng 2 types of rubber bushi ngs. The
front l ower control arm bushi ng i s the spool type and
i s pressed i nto the l ower control arm, whi l e the rear
uses a bushi ng that i s pushed over a stem on the
l ower control arm. The front and rear of the l ower
control arm i s mounted to the cast crossmember
usi ng a pi vot bol t through the center of the front
pi vot bushi ng, and a retai ner whi ch traps the rear
bushi ng i n the crossmember.
The bal l joi nt i s pressed i nto the control arm and
has a non-tapered stud wi th a notch for cl amp bol t
cl earance. The stud i s cl amped and l ocked i nto the
steeri ng knuckl e l eg wi th a cl amp bol t.
The bal l joi nt i s l ubri cated for the l i fe of the vehi -
cl e and does not requi re any peri odi c l ubri cati on.
STABILIZER BAR
The stabi l i zer bar i nterconnects both Mc Pherson
strut assembl i es of the vehi cl e and i s attached
through rubber i sol ator bushi ngs to the front suspen-
si on cradl e
Jounce and rebound movements affecti ng one
wheel are parti al l y transmi tted to the opposi te wheel
to stabi l i ze body rol l .
Attachment of the stabi l i zer bar to the front sus-
pensi on cradl e i s through 2 rubber-i sol ator bushi ngs
and bushi ng retai ners. The stabi l i zer bar to Mc Pher-
son strut assembl y attachment i s done uti l i zi ng a
sway bar attachi ng l i nk. Al l parts of the stabi l i zer
bar are servi ceabl e, and the stabi l i zer bar to cross-
member bushi ngs are spl i t for easy removal and
i nstal l ati on. The spl i t i n the stabi l i zer bar to cross-
member bushi ng shoul d be posi ti oned toward the
rear of the vehi cl e, wi th the square corner down
toward the ground, when the stabi l i zer bar i s
i nstal l ed i n the vehi cl e.
STABILIZER BAR ATTACHING LINK
The stabi l i zer bar attachi ng l i nks are used to
attach each end of the stabi l i zer bar to the front
strut assembl i es. Thi s reduces the fore-and-aft rate of
the stabi l i zer bar from the rest of the vehi cl es front
suspensi on.
HUB AND BEARING ASSEMBLY
The Uni t I I I Front Hub and Beari ng Assembl y i s
used on al l front wheel dri ve vans.
Al l hub and beari ng assembl i es mount to the steer-
i ng knuckl e the same way, but very by the wheel si ze
on the vehi cl e. Vehi cl es equi pped wi th 14 i nch wheel s
have a 4 i nch wheel mounti ng stud pattern. Vehi cl es
equi pped wi th 15 i nch wheel s have a 4 1/2 i nch
wheel mounti ng stud pattern. I f a hub and beari ng
assembl y needs to be repl aced, be sure that the
repl acement assembl y has the same si ze wheel
mounti ng stud pattern as the ori gi nal part.
Thi s uni t i s servi ced onl y as a compl ete assembl y.
I t i s mounted to the steeri ng knuckl e by four mount-
i ng bol ts that are removed from the rear of the steer-
i ng knuckl e.
Fig. 1 Front Steering Knuckle
2 - 10 SUSPENSION NS
COIL SPRING
Coi l spri ngs are rated separatel y for each corner or
si de of the vehi cl e dependi ng on opti onal equi pment
and type of vehi cl e servi ce. Duri ng servi ce procedures
when both spri ngs are removed, mark spri ngs to
ensure i nstal l ati on i n ori gi nal posi ti on. Each coi l
spri ng comes wi th a pl asti c sl eeve on the second coi l
of the spri ng. Thi s pl asti c sl eeve i s a noi se i nsul ator
for the coi l spri ng.
NOTE: If coil springs require replacement, be sure
that the springs needing replacement, are replaced
with springs meeting the correct load rating for the
vehicle and its specific options.
BALL JOINT
The bal l joi nt (Fi g. 2) i s pressed i nto the l ower con-
trol arm. The bal l joi nt has a non-tapered stud wi th
a notch (Fi g. 2) to provi de cl earance for the steeri ng
knuckl e cl amp bol t and to provi de retenti on of the
bal l stud i n the steeri ng knuckl e. The bal l joi nt stud
i s cl amped and l ocked i nto the steeri ng knuckl e l eg
usi ng a pi nch bol t. The bal l joi nt used on thi s vehi cl e
i s repl aceabl e and i f found defecti ve can be servi ced
as a separate component of the l ower control arm
assembl y.
WHEEL MOUNTING STUDS
I f wheel attachi ng studs need to be repl aced i n the
hub and beari ng assembl y the studs CAN NOT be
hammered out of the hub fl ange. I f a stud i s removed
by hammeri ng i t out of the beari ng fl ange, damage to
the hub and beari ng assembl y wi l l occur l eadi ng to
premature beari ng fai l ure.
Use the procedure and speci al tool s shown i n the
servi ce procedures secti on for the wheel mounti ng
studs when repl aci ng the wheel attachi ng studs.
The hub and beari ng assembl y does not requi re
removal from the steeri ng knuckl e or the rear
knuckl e to repl ace the wheel attachi ng studs i n the
hub and beari ng assembl y.
Mc PHERSON STRUT
(1) I nspect for damaged or broken coi l spri ngs (Fi g. 3).
(2) I nspect for torn or damaged strut assembl y
dust boots (Fi g. 3).
(3) I nspect the coi l spri ng i sol ator on the l ower
spri ng seat, (Fi g. 3) for any si gns of damage or dete-
ri orati on.
(4) Li ft dust boot (Fi g. 4) and i nspect strut assembl y for
evi dence of fl ui d runni ng from the upper end of fl ui d res-
ervoi r. (Actual l eakage wi l l be a stream of fl ui d runni ng
down the si de and dri ppi ng off l ower end of uni t). A sl i ght
amount of seepage between the strut rod and strut shaft
seal i s not unusual and does not affect performance of the
strut assembl y (Fi g. 4). Al so i nspect jounce bumpers for
si gns of damage or deteri orati on.
Fig. 2 Ball Joint Assembly
Fig. 3 Mc Pherson Strut Assembly Inspection
Fig. 4 Strut Assembly Leakage Inspection
NS SUSPENSION 2 - 11
STEERING KNUCKLE
The front suspensi on knuckl e i s not a repai rabl e
component of the vehi cl es front suspensi on IT MUST
BE REPLACED. I f bent, broken or damaged i n any
way, do not attempt to strai ghten or repai r the steer-
i ng knuckl e.
Servi ce repl acement of the front hub/beari ng
assembl y can be done wi th the front steeri ng knuckl e
remai ni ng on the vehi cl e.
LOWER CONTROL ARM
I f damaged, the l ower control arm casti ng i s ser-
vi ced onl y as a compl ete component. I nspect l ower
control arm for si gns of damage from contact wi th
the ground or road debri s. I f l ower control arm shows
any si gn of damage, i nspect l ower control arm for
di storti on. Do not attempt to repair or straighten
a broken or bent lower control arm.
The servi ceabl e components of the l ower control
arm are: the bal l joi nt assembl y, bal l joi nt assembl y
grease seal and control arm bushi ngs. I nspect both
control arm bushi ngs for severe deteri orati on, and
repl ace i f requi red. I nspect bal l joi nt per i nspecti on
procedure i n thi s secti on of the servi ce manual and
repl ace i f requi red. Servi ce procedures to repl ace
these components are detai l ed i n the speci fi c compo-
nent removal and i nstal l ati on secti ons i n thi s group
of the servi ce manual .
BALL JOINT (LOWER)
Wi th the wei ght of the vehi cl e resti ng on the road
wheel s, grasp the grease fi tti ng as shown i n (Fi g. 5)
and wi th no mechani cal assi stance or added force
attempt to rotate the grease fi tti ng.
I f the bal l joi nt i s worn the grease fi tti ng wi l l
rotate easi l y. I f movement i s noted, repl acement of
the bal l joi nt i s recommended.
STABILIZER BAR
I nspect for broken or di storted sway bar bushi ngs,
bushi ng retai ners, and worn or damaged sway bar to
strut attachi ng l i nks. I f sway bar to front suspensi on
cradl e bushi ng repl acement i s requi red, bushi ng can
be removed from sway bar by openi ng sl i t and peel -
i ng bushi ng off sway bar.
The condi ti on of the front hub and beari ng assem-
bl y i s di agnosed usi ng the i nspecti on and testi ng pro-
cedure detai l ed bel ow.
The beari ng contai ned i n the Uni t I I I front hub/
beari ng assembl y wi l l produce noi se and vi brati on
when worn or damaged. The noi se wi l l general l y
change when the beari ngs are l oaded. A road test of
the vehi cl e i s normal l y requi red to determi ne the
l ocati on of a worn or damaged beari ng.
Fi nd a smooth l evel road surface and bri ng the
vehi cl e up to a constant speed. When vehi cl e i s at a
constant speed, swerve the vehi cl e back and forth
from the l eft and to the ri ght. Thi s wi l l l oad and
unl oad the beari ngs and change the noi se l evel .
Where axl e beari ng damage i s sl i ght, the noi se i s
usual l y not noti ceabl e at speeds above 30 m.p.h..
SERVICE PROCEDURES
SUSPENSION CRADLE THREAD REPAIR
PROCEDURE
WARNING: When performing this procedure use
only the thread inserts which are specified in the
Mopar Parts Catalog for this repair procedure.
These thread inserts have been specifically devel-
oped for this application and use of other types of
thread inserts can result in an inferior long term
repair.
The threaded hol es i n the front suspensi on cradl e,
i f damaged, can repai red by i nstal l i ng a Hel i -Coi l
thread i nsert.
The threaded hol es that are repai rabl e usi ng the
thread i nsert, are the l ower control arm rear bushi ng
retai ner mounti ng bol t hol es, routi ng bracket attach-
i ng l ocati ons for the power steeri ng hoses, and brake
hose attachment hol es.
Thi s repai r procedure now al l ows the threaded
hol es i n the suspensi on crossmember to be repai red,
el i mi nati ng the need to repl ace the crossmember i f
damage occurs to one of the threaded hol es.
The thread i nserts for thi s appl i cati on are speci fi ed
by part number i n the Mopar Parts Catal og. Do not
use a substitute thread insert.
The speci fi c tool s and equi pment requi red to i nstal l
the thread i nsert are l i sted bel ow. Refer to the
Fig. 5 Checking Ball Joint Wear
i nstructi ons i ncl uded wi th the thread i nsert for the
detai l ed procedure used for the i nstal l ati on of the
thread i nsert.
NOTE: The thread inserts for this application are
for the repair of M8x1.25 and M10x1.5 threads. Be
sure the correct tools are used for the required
thread insert size.
TOOL REQUIREMENT FOR M8x1.25 Thread
8.3mm (5/16 i n.) Dri l l Bi t
120 Countersi nk
Hel i -Coi l Tap #4863-8
Hel i -Coi l Gage #4624-8
Hel i -Coi l Hand I nserti ng Tool 7751-8
Needl e Nose Pl i ers For Removal Of Thread
I nsert Dri vi ng Tang
TOOL REQUIREMENT FOR M10x1.5 Thread
10.5mm (25/64 i n.) Dri l l Bi t
120 Countersi nk
Hel i -Coi l Tap #4863-10
Hel i -Coi l Gage #4624-10
Hel i -Coi l Hand I nserti ng Tool 7751-10
Needl e Nose Pl i ers For Removal Of Thread
I nsert Dri vi ng Tang
Mc PHERSON STRUT
REMOVAL
WARNING: DO NOT REMOVE THE NUT FROM THE
STRUT ROD WHILE STRUT ASSEMBLY IS
INSTALLED IN VEHICLE, OR BEFORE STRUT
ASSEMBLY SPRING IS COMPRESSED.
(1) Rai se vehi cl e on jack stands or centered on a
frame contact type hoi st. See Hoi sti ng i n the Lubri -
cati on and Mai ntenance secti on of thi s servi ce man-
ual , for the requi red l i fti ng procedure to be used for
thi s vehi cl e.
(2) Remove the wheel and ti re assembl y from l oca-
ti on on front of vehi cl e requi ri ng strut removal .
(3) I f both strut assembl i es are to be removed,
mark the strut assembl i es ri ght or l eft accordi ng to
whi ch si de of the vehi cl e they were removed from.
(4) Remove the hydraul i c brake hose routi ng
bracket and the speed sensor cabl e routi ng bracket
from the strut damper brackets (Fi g. 6).
NOTE: When removing nut from stud of stabilizer
bar attaching link, do not allow stud to rotate. Hold
stud from rotating by inserting a Torx Plus 40IP bit
in the end of the stud as shown in (Fig. 7).
(5) Remove the stabi l i zer bar attachi ng l i nk (Fi g.
7) from the bracket on the strut assembl y.
CAUTION: The steering knuckle to strut assembly
(6) Remove the 2 strut assembl y cl evi s bracket to
steeri ng knuckl e attachi ng bol ts (Fi g. 8).
(7) Remove the 3 nuts attachi ng the strut assem-
bl y upper mount to the strut tower (Fi g. 9).
INSTALLATION
(1) I nstal l strut assembl y i nto strut tower, al i gni ng
and i nstal l i ng the 3 studs on the upper strut mount
i nto the hol es i n shock tower. I nstal l the 3 upper
strut mount attachi ng nut/washer assembl i es (Fi g.
9). Then usi ng a crow foot. ti ghten the 3 attachi ng
nuts to a torque of 28 Nm (250 i n. l bs.).
Fig. 6 Brake Hose And Speed Sensor Cable Routing
Fig. 7 Stabilizer Bar Link To Strut Attachment
during installation. Install nuts while holding bolts
(2) Al i gn strut assembl y wi th steeri ng knuckl e.
Posi ti on arm of steeri ng knuckl e i nto strut assembl y
cl evi s bracket. Al i gn the strut assembl y cl evi s
bracket mounti ng hol es wi th the steeri ng knuckl e
mounti ng hol es. I nstal l the 2 strut assembl y to steer-
i ng knuckl e attachi ng bol ts (Fi g. 8). If strut assem-
bly is attached to steering knuckle using a cam
bolt, the cambolt must be installed in the lower
slotted hole on strut clevis bracket. Also,
attaching bolts should be installed with the
nuts facing the front of the vehicle (Fig. 8).
Tighten the strut assembly to steering knuckle
attaching bolts to a torque of 88 Nm(65 ft. lbs.)
plus an additional 1/4 turn after specified
torque is met.
(3) I nstal l stabi l i zer bar attachi ng l i nk (Fi g. 7) on
bracket of strut assembl y. I nstal l stabi l i zer bar
attachi ng l i nk to strut bracket attachi ng nut.
NOTE: When torquing nut on stud of stabilizer bar
attaching link, do not allow stud to rotate. Hold stud
from rotating by inserting a Torx Plus 40IP bit in the
end of the stud as shown in (Fig. 10).
(4) Ti ghten the stabi l i zer bar l i nk to strut attach-
i ng nut usi ng a Torx Pl us 40I P bi t and crowfoot as
shown i n (Fi g. 10) to a torque of 88 Nm (65 ft. l bs.).
(5) I nstal l hydraul i c brake hose and speed sensor
cabl e routi ng brackets on the strut assembl y brackets
(Fi g. 6). Ti ghten the routi ng bracket attachi ng bol ts
to a torque of 13 Nm (10 ft. l bs.).
(6) I nstal l the wheel /ti re assembl y on the vehi cl e.
(7) I nstal l and ti ghten the wheel mounti ng stud
nuts i n proper sequence unti l al l nuts are torqued to
hal f speci fi cati on. Then repeat the ti ghteni ng
sequence to the ful l speci fi ed torque of 135 Nm (100
ft. l bs.).
STEERING KNUCKLE
REMOVE
cati on And Mai ntenance Secti on of thi s manual for
the requi red l i fti ng procedure to be used for thi s
vehi cl e.
(2) Remove the cotter pi n and nut l ock (Fi g. 11)
from the end of the stub axl e.
(3) Remove the wheel and ti re assembl y from the
vehi cl e.
(4) Remove the wave washer (Fi g. 12) from the
end of the stub axl e
Fig. 8 Strut Damper Attachment To Steering
Knuckle
Fig. 9 Strut Assembly To Strut Tower Attaching
Nuts
Fig. 10 Torquing Stabilizer Bar Link To Strut
Attaching Nut
REMOVAL AND INSTALLATION (Continued)
CAUTION: Wheel bearing damage will result if after
loosening hub nut, vehicle is rolled on the ground
or the weight of the vehicle is allowed to be sup-
ported by the tires.
(5) Wi th the vehi cl es brakes appl i ed to keep hub
from turni ng, loosen and remove the stub axl e to
hub nut.
(6) Remove the 2 front di sc brake cal i per to steer-
i ng knuckl e attachi ng bol ts (Fi g. 13).
(7) Remove the di sc brake cal i per from the steer-
i ng knuckl e. Cal i per i s removed by fi rst rotati ng top
of cal i per away from steeri ng knuckl e and then
removi ng bottom of cal i per out from under machi ned
abutment on steeri ng knuckl e (Fi g. 14).
(8) Support di sc brake cal i per assembl y by usi ng a
wi re hook and suspendi ng i t from the strut assembl y
(Fi g. 15). Do not allow the brake caliper assem-
bly to hang by the brake flex hose.
Fig. 11 Hub/Bearing To Stub Axle Retaining Nut
Fig. 12 Wave Washer
Fig. 13 Front Disc Brake Caliper Attaching Bolts
Fig. 14 Brake Caliper Mounting To Steering Knuckle
Fig. 15 Correctly Supported Disc Brake Caliper
(9) Remove the brake rotor from the hub and bear-
i ng assembl y (Fi g. 16).
(10) Remove nut attachi ng outer ti e rod end to
steeri ng knuckl e (Fi g. 17). Nut is to be removed
from tie rod end using the following procedure,
hold tie rod end stud with a 11/32 socket while
loosening and removing nut with a wrench.
(11) Remove ti e rod end from steeri ng knuckl e
usi ng Remover, Speci al Tool MB-991113 (Fi g. 18).
(12) Remove the front wheel speed sensor (Fi g. 19)
from the steeri ng knuckl e.
(13) I f equi pped, remove the wheel stop (Fi g. 20)
from the steeri ng knuckl e. When installing the
pinch bolt when assembling the steering
knuckle to the ball joint, the pinch bolt must be
installed from the rear facing the front on the
vehicle.
Fig. 16 Remove/Install Brake Rotor
Fig. 17 Removing Tie Rod End Attaching Nut
Fig. 18 Tie Rod End Removal From Steering
Knuckle Arm
Fig. 19 Front Wheel Speed Sensor
Fig. 20 Wheel Stop Location On Steering Knuckle
(14) Remove the steeri ng knuckl e to bal l joi nt
stud, cl ampi ng nut and bol t (Fi g. 21) from the steer-
i ng knuckl e.
(15) Usi ng a pry bar, separate steeri ng knuckl e
from bal l joi nt stud (Fi g. 22). Note: Use caution
when separating ball joint stud from steering
knuckle, so ball joint seal does not get cut.
NOTE: Care must be taken not to separate the
inner C/V joint during this operation. Do not allow
driveshaft to hang by inner C/V joint after removing
outer C/V Joint from the hub/bearing assembly in
steering knuckle, end of driveshaft must be sup-
ported.
(16) Pul l steeri ng knuckl e assembl y out and away
from the outer C/V joi nt of the dri veshaft assembl y
(Fi g. 23).
(17) Remove the 2 steeri ng knuckl e to strut
damper cl evi s bracket attachi ng bol ts (Fi g. 24).
(18) Remove the steeri ng knuckl e from the strut.
INSTALL
(1) Transfer, or i nstal l i f necessary, a new hub/
beari ng assembl y i nto the steeri ng knuckl e. Refer to
Hub And Beari ng Assembl y Servi ce i n thi s secti on of
the servi ce manual for the requi red removal and
i nstal l ati on procedure for the front hub/beari ng
assembl y.
during installation. Install nuts while holding bolts
Fig. 21 Control Arm To Steering Knuckle
Attachment
Fig. 22 Separating Ball Joint Stud From Steering
Knuckle
Fig. 23 Steering Knuckle Separation From
Driveshaft
Fig. 24 Strut To Steering Knuckle Attaching Bolts
CAUTION: If the vehicle being serviced is
equipped with eccentric strut assembly attaching
bolts, the eccentric bolt must be installed in the
bottom (slotted) hole on the strut clevis bracket
(Fig. 25).
(2) I nstal l steeri ng knuckl e back i n cl evi s bracket
of strut damper assembl y (Fi g. 24). I nstal l the strut
damper to steeri ng knuckl e attachi ng bol ts. Ti ghten
both attachi ng bol ts to a torque of 90 Nm (65 ft. l bs.)
pl us an addi ti onal 1/4 turn.
(3) Sl i de dri ve shaft back i nto front hub and bear-
i ng assembl y. Then i nstal l steeri ng knuckl e onto the
stud of the bal l joi nt assembl y (Fi g. 23).
(4) I nstal l a NEW steeri ng knuckl e to bal l joi nt
stud, cl ampi ng bol t and nut (Fi g. 21). Ti ghten the
cl ampi ng bol t and nut to a torque of 145 Nm (105 ft.
l bs.).
(5) I nstal l ti e rod end i nto steeri ng knuckl e. Start
attachi ng nut onto stud of ti e rod end. Whi l e hol di ng
stud of ti e rod end stati onary usi ng a 11/32 socket,
(Fi g. 17) ti ghten ti e rod end to steeri ng knuckl e
attachi ng nut. Then usi ng a crowfoot and 11/32
socket (Fi g. 26), ti ghten the ti e rod end attachi ng nut
(6) I nstal l braki ng di sc on hub and beari ng assem-
bl y (Fi g. 16).
(7) I nstal l di sc brake cal i per assembl y on steeri ng
knuckl e. Cal i per i s i nstal l ed by fi rst sl i di ng bottom of
cal i per under abutment on steeri ng knuckl e, and
then rotati ng top of cal i per agai nst top abutment
(Fi g. 14).
(8) I nstal l di sc brake cal i per assembl y to steeri ng
knuckl e attachi ng bol ts (Fi g. 13). Ti ghten the di sc
brake cal i per assembl y attachi ng bol ts to a torque of
35 Nm (30 ft. l bs.).
(9) Cl ean al l forei gn matter from the threads of
the outer C/V joi nt stub axl e. I nstal l the washer and
stub axl e to hub/beari ng assembl y nut on stub axl e
and securel y ti ghten nut.
(10) I nstal l wheel speed sensor and mounti ng bol t
(Fi g. 19) on steeri ng knuckl e. Ti ghten the speed sen-
sor attachi ng bol t to a torque of 7 Nm (60 i n. l bs.).
(11) I nstal l front wheel and ti re assembl y. I nstal l
and ti ghten the wheel mounti ng stud nuts i n proper
sequence unti l al l nuts are torqued to hal f the requi red
speci fi cati on. Then repeat the ti ghteni ng sequence to
the ful l speci fi ed torque of 135 Nm (100 ft. l bs.).
(12) Lower vehi cl e.
(13) Wi th the vehi cl es brakes appl i ed to keep hub
from turni ng, ti ghten the hub nut to a torque of 203
Nm (150 ft. l bs.) (Fi g. 27).
(14) I nstal l the spri ng wave washer on the end of
the stub axl e.
(15) I nstal l the hub nut l ock, and a new cotter pi n
(Fi g. 11). Wrap cotter pi n prongs ti ghtl y around the
hub nut l ock as shown i n (Fi g. 11).
(16) Set front Toe on vehi cl e to requi red speci fi ca-
ti on. Use procedure l i sted under Wheel Al i gnment, i n
the Front Suspensi on Servi ce Procedures secti on of
thi s servi ce manual .
Fig. 25 Correctly Installed Eccentric Attaching Bolt
Fig. 26 Torquing Tie Rod End Attaching Nut
Fig. 27 Torquing Front Stub Axle To Hub Nut
LOWER CONTROL ARM
REMOVE
cati on and Mai ntenance secti on of thi s manual , for
vehi cl e.
(2) Remove wheel and ti re assembl y from the si de
of vehi cl e requi ri ng servi ce to the l ower control arm.
(3) Remove the wheel stop (Fi g. 28) from the steer-
i ng knuckl e. When installing the pinch bolt when
assembling the steering knuckle to the ball
joint, the pinch bolt must be installed from the
rear facing the front on the vehicle (Fig. 28).
(4) Remove the nut and bol t cl ampi ng the steeri ng
knuckl e to the bal l joi nt stud. (Fi g. 29)
NOTE: The attaching bolts for the cradle plate are
of two different thread sizes. Nine of the bolts are a
M-14 thread and one of the bolts is a M-12 thread.
Refer to (Fig. 30) for the cradle plate attaching bolt
locations.
(5) Remove the 10 bol ts (Fi g. 30) attachi ng the cra-
dl e pl ate to the front suspensi on cradl e. Then remove
the cradl e pl ate from the cradl e.
CAUTION: Pulling steering knuckle out from vehi-
cle after releasing from ball joint can separate inner
C/V joint. See Driveshafts.
(6) Usi ng a pry bar, separate steeri ng knuckl e
from bal l joi nt stud (Fi g. 31). Use caution when
separating ball joint stud from steering
knuckle, so ball joint seal does not get cut.
Fig. 28 Wheel Stop Location On Steering Knuckle
Fig. 29 Control Arm To Steering Knuckle
Attachment
Fig. 30 Front Suspension Cradle Plate And
Mounting Bolts
Fig. 31 Separating Ball Joint Stud From Steering
Knuckle
(7) Loosen but do not remove the pi vot bol t (Fi g.
32) attachi ng the front bushi ng of the l ower control
arm to the front suspensi on cradl e.
(8) Remove retai ner (Fi g. 33) attachi ng rear bush-
i ng of l ower control arm to front suspensi on cradl e.
CAUTION: Make location reference marks where
the front suspension cradle is mounted against the
front frame rails before loosening and lowering the
cradle. This is required so the cradle can be re-in-
stalled in the design location to achieve proper
front suspension alignment.
(9) Loosen but not ful l y removi ng the 2 l eft si de
suspensi on cradl e to frame rai l attachi ng bol ts (Fi g.
34).
NOTE: When removing the left lower control arm
from the vehicle, the front suspension cradle needs
to be lowered for the pivot bolt to clear the tran-
saxle.
(10) Lower the l eft front corner of the suspensi on
cradl e unti l pi vot bol t wi l l cl ear end of transaxl e (Fi g.
35). Remove the pi vot bol t and the l ower control arm
from the cradl e.
INSTALL
NOTE: If the left lower control arm is being
installed on the vehicle the front suspension cradle
needs to be lowered for the pivot bolt to clear the
transaxle.
(1) Posi ti on l ower control arm assembl y i nto front
suspensi on cradl e. If installing the left lower con-
trol arm, pry down on the left front corner of
the suspension cradle until the pivot bolt clears
the end of the transaxle (Fig. 35). I nstal l pi vot
bol t attachi ng front bushi ng of l ower control arm to
front
Fig. 32 Lower Control Arm Bushing To Cradle Pivot
Bolt
Fig. 33 Control Arm Bushing To Suspension Cradle
Retainer
Fig. 34 Suspension Cradle To Frame Rail Mounting
Bolts
Fig. 35 Lowering Front Suspension Cradle
suspensi on cradl e (Fi g. 36). Do not tighten or
torque pivot bolt at this time.
(2) I nstal l retai ner (Fi g. 37) attachi ng rear bush-
i ng of l ower control arm to front suspensi on cradl e.
When installing retainer, be sure raised rib on
rear bushing (Fig. 37) is positioned in the
groove on the retainer. Do not torque attaching
bolts at this time.
NOTE: If reference marks were not put on the
frame rails prior to lowering the suspension cradle,
Refer to group 13 Frame And Bumpers for the cra-
dle positioning procedure.
(3) Rai se the front suspensi on cradl e agai nst the
front frame rai l s. Al i gn the cradl e wi th the reference
marks on the frame rai l s.
(4) Ti ghten the 4 mounti ng bol ts for the front sus-
pensi on cradl e to a torque of 163 Nm (120 ft. l bs.).
(5) I nstal l l ower control arm bal l joi nt stud i nto
steeri ng knuckl e. Then i nstal l the bol t and nut,
cl ampi ng the steeri ng knuckl e to the bal l joi nt stud
(Fi g. 29). Ti ghten the cl ampi ng bol t to a torque of
145 Nm (105 ft. l bs.).
(6) I nstal l the cradl e pl ate on front suspensi on cra-
dl e and then i nstal l the 10 cradl e pl ate to cradl e
attachi ng bol ts (Fi g. 30). Ti ghten the 9 M-14 attach-
i ng bol ts (Fi g. 30) to a torque of 165 Nm (123 ft.
l bs.). Ti ghten the 1 M-12 attachi ng bol t (Fi g. 30) to a
torque of 108 Nm (80 ft. l bs.).
CAUTION: When locating jack stands under lower
control arm, do not place the jack stands under the
ball joints (Fig. 38).
(7) Posi ti on jack stands under the l ower control
arms as cl ose to the bal l joi nts as possi bl e (Fi g. 38).
Lower the vehi cl e onto the jack stands, unti l the jack
stands are supporti ng the total wei ght of the vehi cl e
(Fi g. 38).
(8) Ti ghten front l ower control arm pi vot bol t (Fi g.
36) to a torque of 183 Nm (135 ft. l bs.) fi rst, then
ti ghten rear l ower control arm bushi ng retai ner
attachi ng bol ts (Fi g. 33) to a torque of 68 Nm (50 ft.
l bs.).
(9) I nstal l the wheel /ti re assembl y on the vehi cl e.
(10) I nstal l and ti ghten the wheel mounti ng stud
nuts i n proper sequence unti l al l nuts are torqued to
hal f speci fi cati on. Then repeat the ti ghteni ng
sequence to the ful l speci fi ed torque of 135 Nm (100
ft. l bs.).
(11) Remove jack stands and l ower vehi cl e to the
ground.
Fig. 36 Lower Control Arm Bushing Pivot Bolt
Correctly Installed
Fig. 37 Installing Lower Control Arm Rear Bushing
Retainer
Fig. 38 Jack Stands Supporting Vehicle Weight
BALL JOINT
REMOVE
(1) Usi ng a screw dri ver or other sui tabl e tool , pry
the seal boot off of the bal l joi nt assembl y (Fi g. 39)
(2) Posi ti on recei vi ng cup, Speci al Tool 6758 to
support l ower control arm when removi ng bal l joi nt
assembl y (Fi g. 40). I nstal l Remover, Speci al Tool
6919 on top of the bal l joi nt assembl y (Fi g. 40).
(3) Usi ng the arbor press, press the bal l joi nt
assembl y compl etel y out of the l ower control arm.
INSTALL
NOTE: When installing ball joint in lower control
arm, position the ball joint in control arm so notch
in ball joint stud is in the direction shown (Fig. 41).
This will ease assembly of the ball joint to the
steering when installing pinch bolt.
(1) By hand, posi ti on bal l joi nt i nto bal l joi nt bore
of l ower control arm. Be sure ball joint is not
cocked in the bore of the control arm, this will
cause the ball joint to bind when being pressed
into control arm.
(2) Posi ti on control arm wi th i nstal l ed bal l joi nt, i n
an arbor press wi th Recei vi ng Cup, Speci al Tool 6758
supporti ng the l ower control arm (Fi g. 42). Then cen-
ter I nstal l er, Speci al Tool 69084 on the bottom of
the bal l joi nt (Fi g. 42)
(3) Careful l y al i gn al l pi eces. Then press the bal l
joi nt i nto the l ower control arm unti l i t i s compl etel y
seated agai nst surface of l ower control arm. The bal l
joi nt i s correctl y i nstal l ed when there i s no gap
between the bal l joi nt and the l ower control arm (Fi g.
43). Do not apply excessive force against the
ball joint or the lower control arm.
Fig. 39 Ball Joint Seal Boot Removal
Fig. 40 Ball Joint Removal From Lower Control Arm
Fig. 41 Installation Position Of Ball Joint In Control
Arm
Fig. 42 Installing Ball Joint In Control Arm
CAUTION: When installing the ball joint seal on the
ball joint/lower control arm, the shield (Fig. 44) on
the ball joint seal must be positioned as shown.
(4) I nstal l a NEWseal boot by hand as far as pos-
si bl e on the bal l joi nt. I nstal l ati on of the seal boot i s
to be wi th the shi el d posi ti oned as shown (Fi g. 44).
CAUTION: Do not use an arbor press to install the
sealing boot on the ball joint. Damage to the seal-
ing boot will occur if excessive pressure is applied
to the sealing boot when it is being installed.
(5) Pl ace I nstal l er, Speci al Tool 6758 over seal boot
and squarel y al i gn i t wi th bottom edge of seal boot
(Fi g. 45). Appl y hand pressure to Speci al Tool 6758
unti l seal boot i s pressed squarel y agai nst top surface
of l ower control arm.
CAUTION: A replacement ball joint is not prelubri-
cated. Properly lubricate the replacement ball joint
using Mopar MultiMile grease or an equivalent.
Lubricate ball joint after seal boot is installed but
prior to top of seal boot being pushed down below
notch in ball joint stud (Fig. 41). Air must vent out
of the seal boot at notch when grease is pumped
into ball joint, failure to do so will balloon and dam-
age seal boot. Do not over grease the ball joint, this
will prevent the seal boot from pushing down on
the stud of the ball joint.
CAUTION: After the ball joint is properly greased,
clip the end of the grease fitting off below the hex.
The ball joint seal boot is non-purgeable and further
greasing is not required and can result in damage
to the seal boot.
STABILIZER BAR
REMOVE
vehi cl e.
NOTE: The attaching bolts for the cradle plate are
of two different thread sizes. Nine of the bolts are a
M-14 thread and one of the bolts is a M-12 thread.
Refer to (Fig. 46) for the cradle plate attaching bolt
locations.
(2) Remove the 10 bol ts (Fi g. 46) attachi ng the cra-
dl e pl ate to the front suspensi on cradl e. Then remove
the cradl e pl ate from the cradl e.
NOTE: When removing nut from stud of stabilizer
bar attaching link, do not allow the stud to rotate.
Hold stud from rotating by inserting a Torx Plus 40
IP bit in the end of the stud (Fig. 47).
Fig. 43 Correctly Installed Lower Ball Joint
Fig. 44 Ball Joint Seal Boot Installed Position
Fig. 45 Installing Ball Joint Seal Boot
(3) Remove the nuts (Fi g. 47) attachi ng the stabi -
l i zer bar attachi ng l i nks to the stabi l i zer bar. Then
remove the attachi ng l i nks from the stabi l i zer bar.
(4) Remove the stabi l i zer bar bushi ng retai ners
from the front suspensi on cradl e (Fi g. 48).
(5) Remove the stabi l i zer bar and bushi ngs as an
assembl y from the front suspensi on cradl e.
INSTALL
(1) I f the stabi l i zer bar to front suspensi on cradl e
bushi ngs requi re repl acement at ti me of i nspecti on,
i nstal l new bushi ngs before i nstal l i ng stabi l i zer bar.
Bushi ngs are repl aced by openi ng sl i t on bushi ngs
and peel i ng them off stabi l i zer bar. I nstal l new bush-
i ngs on stabi l i zer bar by spreadi ng bushi ng at sl i t
and forci ng them on the stabi l i zer bar. Bushings
must be installed on stabilizer bar so slit in
bushing will be facing toward the rear of vehi-
cle with the square corner toward the ground,
when the stabilizer bar is installed on the vehi-
cle (Fig. 49).
(2) Posi ti on stabi l i zer bar i nto front suspensi on
cradl e so stabi l i zer bar bushi ngs are al i gned wi th
depressi ons i n cradl e. I nstal l stabi l i zer bar bushi ng
retai ners onto crossmember al i gni ng rai sed bead on
retai ner wi th cutouts i n bushi ngs (Fi g. 50). Do not
tighten Stabilizer bar bushing retainers at this
time.
(3) Check posi ti on of the stabi l i zer bar i n the front
suspensi on cradl e. The center of the curved secti on of
the stabi l i zer bar must be al i gned wi th the rai sed
l i ne i n the center of the front suspensi on cradl e (Fi g.
51).
(4) Al i gn hol es i n stabi l i zer bar wi th attachi ng l i nk
assembl i es. I nstal l the stabi l i zer bar attachi ng l i nks
i nto the stabi l i zer bar and i nstal l the attachi ng nuts
(Fi g. 47).
Fig. 46 Cradle Plate And Mounting Bolts
Fig. 47 Stabilizer Bar Link Attachment To Stabilizer
Bar
Fig. 48 Front Stabilizer Bar Bushing Retainers
Fig. 49 Correctly Installed Stabilizer Bar To Cradle
Bushing
NOTE: When torquing nut on stud of stabilizer bar
attaching link, do not allow the stud to rotate. Hold
stud from rotating by inserting a Torx Plus 40 IP bit
in the end of the the stud (Fig. 47).
(5) Ti ghten the stabi l i zer bar attachi ng l i nk nuts
(Fi g. 47) to a torque of 88 Nm (65 ft. l bs.).
(6) Ti ghten the stabi l i zer bar bushi ng retai ner to
cradl e attachi ng bol ts (Fi g. 48) to 68 Nm (50 ft. l bs.)
torque.
(7) I nstal l the cradl e pl ate on front suspensi on cra-
dl e and then i nstal l the 10 cradl e pl ate to cradl e
attachi ng bol ts (Fi g. 46). Ti ghten the 9 M-14 attach-
i ng bol ts (Fi g. 46) to a torque of 165 Nm (123 ft.
l bs.). Ti ghten the 1 M-12 attachi ng bol t (Fi g. 46) to a
REMOVE
NOTE: Replacement of the Unit III front hub/bearing
assembly can be normally done without having to
remove the steering knuckle from the vehicle. In the
event that the hub/bearing is frozen in the steering
knuckle and cannot be removed by hand it will have
to be pressed out of the steering knuckle. The
steering knuckle will require removal from the vehi-
cle to allow the hub/bearing assembly to be
pressed out of the steering knuckle. Refer to Front
Steering Knuckle in this section of the service man-
ual for the required removal and installation proce-
dure.
(1) Remove the cotter pi n, and nut l ock from the
stub axl e (Fi g. 52).
(2) Remove the spri ng wave washer (Fi g. 53) from
the end of the stub axl e.
Fig. 50 Stabilizer Bar Bushing Retainer Installation
Fig. 51 Stabilizer Bar Correctly Positioned In Cradle
Fig. 52 Cotter Pin And Nut Lock
Fig. 53 Nut Lock Wave Washer
CAUTION: Wheel bearing damage will result if
after loosening hub nut, vehicle is rolled on the
ground or the weight of the vehicle is allowed to be
supported by the tires.
(3) Wi th the ai d of a hel per appl yi ng the brakes to
keep the front hub from turni ng, loosen but do not
remove the hub nut. The hub and driveshaft are
splined together through the knuckle (bearing)
and retained by the hub nut.
vehi cl e.
(5) Remove wheel l ug nuts, and front ti re and
wheel assembl y.
(6) Remove front di sc brake cal i per to steeri ng
knuckl e attachi ng bol ts. (Fi g. 54).
(7) Remove di sc brake cal i per assembl y from steer-
i ng knuckl e. Cal i per i s removed by fi rst rotati ng top
of cal i per away from steeri ng knuckl e, and then
removi ng bottom of cal i per out from under machi ned
abutment. (Fi g. 55)
(8) Support di sc brake cal i per assembl y usi ng a
wi re hook, (Fi g. 56) do not hang caliper assembly
by hydraulic hose.
(9) Remove the braki ng di sc from the front hub/
beari ng assembl y.
(10) Remove the retai ni ng nut and the washer
(Fi g. 57) from the end of the stub axl e.
(11) Remove the four hub and beari ng assembl y
mounti ng bol ts from the rear of steeri ng knuckl e
(Fi g. 58).
(12) Remove the hub and beari ng assembl y from
the steeri ng knuckl e (Fi g. 59).
Fig. 54 Front Disc Brake Caliper Mounting Bolts
Fig. 55 Brake Caliper Assembly Removal/Installation
Fig. 56 Supporting Brake Caliper
Fig. 57 Hub/Bearing To Stub Axle Retaining Nut And
Washer
INSTALL
CAUTION: Hub and bearing assembly mounting
surfaces on the steering knuckle and halfshaft (Fig.
60) must be smooth and completely free of foreign
material or nicks prior to installing hub and bearing
assembly.
CAUTION: When installing hub and bearing
assembly into steering knuckle, be careful not to
damage the bearing seal (Fig. 60) on the outer C/V
joint.
(1) I nstal l hub/beari ng assembl y onto stub axl e
and i nto steeri ng knuckl e unti l squarel y seated on
the face of the steeri ng knuckl e.
(2) I nstal l the 4 hub/beari ng assembl y to steeri ng
knuckl e attachi ng bol ts (Fi g. 58). Equal l y ti ghten al l
4 mounti ng bol ts i n a cri ss-cross pattern unti l hub/
beari ng assembl y i s squarel y seated agai nst front of
steeri ng knuckl e. Then ti ghten the 4 hub and beari ng
assembl y mounti ng bol ts to a torque of 65 Nm (45
ft.l bs.)
(3) I nstal l the hub/beari ng assembl y to stub shaft
washer and retai ni ng nut (Fi g. 61).Tighten, but do
not torque the hub nut at this time.
(4) I nstal l the braki ng di sk on the hub and beari ng
assembl y.
(5) I nstal l front brake cal i per back over braki ng
di sc and al i gn wi th cal i per mounti ng hol es on steer-
i ng knuckl e (Fi g. 55). Cal i per i s i nstal l ed by fi rst
i nstal l i ng bottom of cal i per under machi ned abut-
ment on bottom of steeri ng knuckl e and then rotat-
i ng top of cal i per toward steeri ng knuckl e. I nstal l the
di sc brake cal i per to steeri ng knuckl e attachi ng bol ts
(Fi g. 54) and ti ghten to a torque of 19 Nm (168 i n.
l bs.).
(6) I nstal l wheel and ti re assembl y on vehi cl e.
Ti ghten the wheel mounti ng stud nuts i n proper
Fig. 58 Hub/Bearing Assembly Mounting Bolts
Fig. 59 Hub and Bearing Assembly Removal From
Steering Knuckle
Fig. 60 Hub And Bearing Assembly Mounting
Surfaces
Fig. 61 Hub/Bearing To Stub Axle Washer And
Retaining Nut
sequence unti l al l nuts are torqued to hal f speci fi ca-
ti on. Then repeat the ti ghteni ng sequence to the ful l
speci fi ed torque of 129 Nm (95 ft. l bs.).
(7) Lower vehi cl e to the ground.
CAUTION: When tightening hub/bearing assembly
to stub shaft retaining nut, do not exceed the max-
imum torque of 244 Nm (180 ft. lbs.).
(8) Wi th vehi cl e brakes appl i ed to keep vehi cl e
from movi ng, torque stub shaft to hub/beari ng assem-
bl y retai ni ng nut to 244 Nm (180 ft. l bs.).
(9) Check the Toe setti ng on the vehi cl e and reset
i f not wi thi n speci fi cati ons.
FRONT WHEEL MOUNTING STUDS
REMOVE
CAUTION: If a wheel attaching stud needs to be
replaced in the hub and bearing assembly the studs
CAN NOT be hammered out of the hub flange. If a
stud is removed by hammering it out of the bearing
flange, damage to the hub and bearing assembly
will occur leading to premature bearing failure.
The fol l owi ng procedure and speci al tool s shown
MUST BE used when repl aci ng wheel attachi ng
studs.
removal from the steeri ng knuckl e to repl ace wheel
attachi ng studs i n the hub and beari ng assembl y.
(1) Rai se vehi cl e on jackstands or centered on a
cati on and Mai ntenance secti on of thi s manual for
vehi cl e.
(2) Remove the front wheel and ti re assembl y from
the vehi cl e.
(3) Remove the front cal i per assembl y from the
front steeri ng knuckl e assembl y. (Fi g. 62) Refer to
Front Di sc Brake Servi ce i n the Brake Secti on of thi s
servi ce manual for cal i per removal procedure.
(4) Remove front rotor from hub, by pul l i ng i t
strai ght off wheel mounti ng studs. (Fi g. 63)
(5) I nstal l a l ug nut on the wheel stud to be
removed from the hub and beari ng assembl y, so the
threads on the stud are even wi th end of l ug nut.
I nstal l Remover, Speci al Tool C-4150A on hub and
beari ng assembl y fl ange and wheel stud (Fi g. 64).
(6) Ti ghteni ng down on speci al tool wi l l push
wheel stud out of the hub and beari ng assembl y
fl ange. When shoul der of wheel stud i s past fl ange
remove speci al tool from hub and beari ng assembl y.
Remove l ug nut from stud and remove wheel stud
from fl ange.
INSTALL
(1) I nstal l repl acement wheel stud i nto fl ange of
hub and beari ng assembl y. I nstal l washers on wheel
stud, then i nstal l a wheel l ug nut on stud wi th fl at
si de of l ug nut agai nst washers (Fi g. 65).
(2) Ti ghten the wheel l ug nut, pul l i ng the wheel
stud i nto the fl ange of the hub and beari ng assembl y.
When the head of the stud i s ful l y seated agai nst the
beari ng fl ange, remove l ug nut and washers from
wheel stud.
(3) I nstal l the braki ng di sk back on the hub and
beari ng assembl y. (Fi g. 63)
Fig. 62 Disc Brake Caliper Mounting
Fig. 63 Removing Braking Disc
(4) I nstal l front brake cal i per back over braki ng
di sc and al i gn wi th cal i per mounti ng hol es on steer-
i ng knuckl e (Fi g. 62). Refer to Front Di sc Brake Ser-
vi ce i n the Brake Secti on of thi s servi ce manual for
cal i per i nstal l ati on procedure. I nstal l the cal i per
adapter to steeri ng knuckl e attachi ng bol ts and
torque to 19 Nm (168 i n. l bs.).
REAR WHEEL MOUNTING STUDS
REMOVE
CAUTION: If a wheel attaching stud needs to be
replaced in the hub and bearing assembly the studs
CAN NOT be hammered out of the hub flange. If a
stud is removed by hammering it out of the bearing
flange, damage to the hub and bearing assembly
will occur leading to premature hub and bearing
failure.
The fol l owi ng procedure and speci al tool s shown
MUST be used when repl aci ng wheel attachi ng
studs.
removal from the rear axl e for repl acement of the
wheel attachi ng studs.
vehi cl e.
(2) Remove the rear wheel and ti re assembl y.
(3) Remove the rear brake drum.
(4) I nstal l a l ug nut on the wheel stud to be
removed from the hub and beari ng assembl y (Fi g. 66)
so the threads on stud are even wi th end of l ug nut.
I nstal l Remover, Speci al Tool C-4150A on hub and
beari ng assembl y fl ange and wheel stud (Fi g. 66).
(5) Ti ghteni ng down on speci al tool wi l l push
wheel stud out of the hub and beari ng assembl y
fl ange. Remove l ug nut from stud and remove wheel
stud from fl ange.
INSTALL
(1) I nstal l repl acement wheel stud i nto fl ange of
hub and beari ng assembl y. I nstal l washers on wheel
stud, then i nstal l a wheel l ug nut on stud wi th fl at
si de of l ug nut agai nst washers (Fi g. 67).
(2) Ti ghten the wheel l ug nut, pul l i ng the wheel
stud i nto the fl ange of the hub and beari ng assembl y.
When the head of the stud i s ful l y seated agai nst the
beari ng fl ange, remove l ug nut and washers from
wheel stud.
Fig. 64 Wheel Stud Removal From Hub/Bearing
Assembly
Fig. 65 Installing Wheel Stud Into Hub And Bearing
Fig. 66 Removing Wheel Stud From Hub And
Bearing
(3) I nstal l the rear brake drum on the hub and
beari ng assembl y.
Mc PHERSON STRUT
DISASSEMBLY
The Mc Pherson Strut must be remove from the
vehi cl e for i t to be di sassembl ed and assembl ed.
Refer to Mc Pherson Strut i n the Removal And
I nstal l ati on Secti on i n thi s group of the servi ce man-
ual for the requi red procedure to remove and i nstal l
the Mc Pherson Strut.
(1) Cl amp strut assembl y i n vi se, wi th strut i n a
verti cal posi ti on. Do not clamp reservoir of strut
assembly in vise, only clamp strut assembly
using strut clevis bracket (Fig. 68).
(2) Mark coi l spri ng and strut assembl y ri ght or
l eft, accordi ng to whi ch si de of vehi cl e strut was
removed from, and whi ch strut coi l spri ng was
removed from.
WARNING: DO NOT REMOVE STRUT ROD NUT,
BEFORE STRUT ASSEMBLY COIL SPRING IS COM-
PRESSED, REMOVING SPRING TENSION FROM
UPPER SPRING SEAT AND BEARING ASSEMBLY.
WARNING: WHEN COMPRESSING COIL SPRING
FOR REMOVAL FROM STRUT ASSEMBLY, THE
UPPER SPRING SEAT AND SECOND COIL OF THE
COIL SPRING MUST BE CAPTURED BY THE JAWS
OF THE COIL SPRING COMPRESSOR (Fig. 69).
(3) Compress strut coi l spri ng, usi ng Pentastar
Servi ce Equi pment Spri ng Compressor, 7522A (Fi g.
69). Be sure the top and bottom attachment shoe
sel ected, (Fi g. 69) properl y fi t the coi l spri ng.
(4) I nstal l Socket, Strut Nut, Speci al Tool 6864 on
the strut shaft retai ni ng nut (Fi g. 70). Then i nstal l a
10 mm socket on the hex of the strut shaft (Fi g. 70).
Whi l e hol di ng strut shaft from turni ng, remove nut
from strut shaft.
(5) Remove the upper mount (Fi g. 71) from the
strut shaft and coi l spri ng upper seat.
(6) Rel ease the coi l spri ng from the spri ng com-
pressor. Remove spri ng compressor from coi l spri ng
(Fi g. 72).
(7) Remove the coi l spri ng upper seat and pi vot
beari ng (Fi g. 72) as an assembl y from the coi l spri ng.
Remove the coi l spri ng from the strut. Mark left
Fig. 67 Installing Wheel Stud Into Hub And Bearing Fig. 68 Strut Assembly Correctly Installed In Vise
Fig. 69 Compressing Strut Assembly Coil Spring
and right springs for installation back on cor-
rect side of vehicle.
(8) Remove the dust shi el d and jounce bumper
(Fi g. 73) as an assembl y from the strut shaft. The
dust shi el d can not be removed from the jounce
bumper unti l after i t i s removed from strut shaft.
(9) Remove the jounce bumper from the dust
shi el d. Jounce bumper i s removed from dust shi el d
by col l apsi ng dust shi el d unti l jounce bumper can be
grabbed and pul l ed out of the dust boot.
(10) Remove the spri ng i sol ator from the l ower
spri ng seat on the strut (Fi g. 74).
(11) I nspect strut damper for any condi ti on of
shaft bi ndi ng over ful l stroke of the shaft.
(12) I nspect the strut mount and the upper spri ng
seat assembl y for the fol l owi ng:
Mount for cracks and di storti on and retai ni ng
studs for any si gn of damage.
Severe deteri orati on of rubber i sol ator,
Bi ndi ng strut assembl y pi vot beari ng. I f pi vot
beari ng i s repl aced i t i s to be i nstal l ed wi th the
l arger di ameter end of beari ng faci ng up.
I nspect dust shi el d for ri ps and/or deteri orati on.
Fig. 70 Strut Shaft Retaining Nut Removal Tools
Fig. 71 Strut Assembly Upper Mount
Fig. 72 Strut Assembly Pivot Bearing And Spring
Seat
Fig. 73 Dust Shield Jounce Bumper
Fig. 74 Strut Lower Spring Seat Isolator
DISASSEMBLY AND ASSEMBLY (Continued)
I nspect jounce bumper for cracks and si gns of
deteri orati on.
(13) Repl ace any components of the strut assembl y
found to be worn or defecti ve duri ng the i nspecti on,
before re-assembl i ng the strut.
ASSEMBLY
(1) Cl amp strut i n vi se, wi th strut i n verti cal posi -
ti on. Do not clamp strut in vise by body of strut,
only by the clevis bracket (Fig. 68).
(2) I nstal l the spri ng i sol ator on the strut l ower
spri ng seat (Fi g. 74). When i nstal l i ng the spri ng i so-
l ator, be sure the 2 retai ni ng tabs on the spri ng i so-
l ator (Fi g. 74) are i nstal l ed i n the 2 hol es i n the
spri ng seat. When properl y i nstal l ed, the oversi ze
hol es i n the spri ng seat shoul d l i ne up wi th the hol es
i n the spri ng i sol ator.
(3) I nstal l the jounce bumper (Fi g. 75) on the strut
shaft. Jounce bumper i s to be i nstal l ed wi th the
smal l end of the jounce bumper poi nti ng down (Fi g.
75).
(4) I nstal l dust shi el d (Fi g. 76) on the strut. After
dust shield is installed on strut, collapse dust
shield down on top of jounce bumper until
jounce bumper snaps into dust shield. Then
return the dust shield to its fully extended
length.
(5) I nstal l coi l spri ng on strut. Spri ng i s to be
i nstal l ed wi th the end of the bottom coi l al i gned wi th
the cl evi s bracket on the strut assembl y (Fi g. 77).
(6) I nstal l the upper spri ng seat on the coi l spri ng
(Fi g. 77). Spri ng seat must be i nstal l ed wi th the
notch i n the spri ng seat (Fi g. 77) al i gned wi th the
cl evi s bracket on the strut.
WARNING: WHEN COMPRESSING THE COIL
SPRING, THE COIL SPRING UPPER SEAT AND THE
BOTTOM COIL OF THE SPRING MUST BE CAP-
TURED BY THE JAWS OF THE COIL SPRING COM-
PRESSOR.
(7) Compress strut coi l spri ng usi ng Pentastar Ser-
vi ce Equi pment Spri ng Compressor, 7522A (Fi g. 69).
Be sure the top and bottom attachment shoe sel ected,
(Fi g. 69) properl y fi t the coi l spri ng.
(8) I nstal l the pi vot beari ng on the top of the
upper spri ng seat (Fi g. 78). Bearing must be
installed on spring seat with the smaller diam-
eter side of the pivot bearing toward the spring
seat (Fig. 78). Also, be sure the pivot bearing is
sitting flat on the spring seat.
(9) I nstal l the strut mount on the upper spri ng
seat of the strut. Loosel y i nstal l the nut on strut
shaft.
WARNING: THE FOLLOWING 2 STEPS MUST BE
COMPLETELY DONE BEFORE SPRING COMPRES-
SOR IS RELEASED FROM THE COIL SPRING.
Fig. 75 Correctly Installed Jounce Bumper
Fig. 76 Installing Dust Boot
Fig. 77 Coil Spring And Spring Seat Correctly
Installed
(10) I nstal l Socket, Strut Nut, Speci al Tool 6864 on
the strut shaft retai ni ng nut (Fi g. 70). Then i nstal l a
10 mm socket on the hex of the strut damper shaft
(Fi g. 70). Whi l e hol di ng strut shaft from turni ng,
torque strut shaft retai ni ng nut to 94 Nm (70 ft.
l bs.).
(11) Loosen spri ng compressor unti l top coi l of
spri ng i s ful l y seated agai nst upper spri ng seat. Then
rel i eve al l tensi on from spri ng compressor and
remove spri ng compressor from strut spri ng.
(12) I nstal l strut back i n vehi cl e. Refer to Mc
Pherson Strut i n the Removal And I nstal l ati on Sec-
ti on i n thi s group of the servi ce manual for the
requi red procedure to i nstal l the Mc Pherson Strut.
BALL JOINT SEAL BOOT
REMOVE
(1) Usi ng a screw dri ver or other sui tabl e tool , pry
the seal boot off of the bal l joi nt assembl y (Fi g. 79)
INSTALL
CAUTION: When installing the ball joint seal on the
ball joint/lower control arm, the shield (Fig. 80) on
the ball joint seal must be positioned as shown.
(1) I nstal l a NEWseal boot by hand as far as pos-
si bl e on the bal l joi nt. I nstal l ati on of the seal boot i s
to be wi th the shi el d posi ti oned as shown (Fi g. 80).
CAUTION: Do not use an arbor press to install the
sealing boot on the ball joint. Damage to the seal-
ing boot will occur if excessive pressure is applied
to the sealing boot when it is being installed.
(2) Pl ace I nstal l er, Speci al Tool 6758 over seal boot
and squarel y al i gn i t wi th bottom edge of seal boot
(Fi g. 81). Appl y hand pressure to Speci al Tool 6758
unti l seal boot i s pressed squarel y agai nst top surface
of l ower control arm.
CAUTION: A replacement ball joint is not prelubri-
cated. Properly lubricate the replacement ball joint
using Mopar MultiMile grease or an equivalent.
Lubricate ball joint after seal boot is installed but
prior to top of seal boot being pushed down below
notch in ball joint stud. Air must vent out of the
seal boot at notch when grease is pumped into ball
joint, failure to do so will balloon and damage seal
boot. Do not over grease the ball joint, this will pre-
vent the seal boot from pushing down on the stud
of the ball joint.
CAUTION: After the ball joint is properly greased,
clip the end of the grease fitting off below the hex.
The ball joint seal boot is non-purgeable and further
greasing is not required and can result in damage
to the seal boot.
Fig. 78 Installing Pivot Bearing On Upper Spring
Seat
Fig. 79 Ball Joint Seal Boot Removal
Fig. 80 Ball Joint Seal Boot Installed Position
LOWER CONTROL ARM FRONT BUSHING
REMOVE
(1) Remove the l ower control arm from the front
suspensi on cradl e. Refer to Lower Control Arm i n the
Removal And I nstal l ati on Secti on i n thi s secti on of
the servi ce manual for the requi red procedure.
(2) Securel y mount the l ower control arm i n a vi se.
(3) Assembl e for removal of the front bushi ng, the
Bushi ng Recei ver, Speci al Tool 69082, Bushi ng
Remover, Speci al Tool 69081, Nut, Speci al Tool
69083 thrust washer, threaded rod and smal l nut,
as shown i n (Fi g. 82) on the l ower control arm and
front bushi ng.
(4) To remove front bushi ng from l ower control
arm, hol d the threaded rod stati onary and ti ghten
the Nut, Speci al Tool 69083 (Fi g. 82). Thi s wi l l force
the front bushi ng out of the l ower control arm and
i nto Bushi ng Recei ver, Speci al Tool 69082 (Fi g. 82).
INSTALL
(1) Securel y mount the l ower control arm i n a vi se.
NOTE: The lower control arm front bushing is a
directional bushing. It must be installed in the lower
control arm positioned as shown in (Fig. 83).
(2) Posi ti on the front bushi ng i n the l ower control
arm so that the 2 rubber bl ocks on the bushi ng are
posi ti oned hori zontal l y as shown i n (Fi g. 83).
(3) Assembl e for i nstal l ati on of the front bushi ng,
the Bushi ng Recei ver, Speci al Tool 69085, Bushi ng
I nstal l er, Speci al Tool 69084, Nut, Speci al Tool
69083 thrust washer, threaded rod and smal l nut,
as shown i n (Fi g. 84) on the l ower control arm and
front bushi ng.
(4) To i nstal l the front bushi ng i n l ower control
arm, hol d the threaded rod stati onary and ti ghten
Fig. 81 Installing Ball Joint Seal Boot
Fig. 82 Tools Assembled For Removal Of Front
Bushing
Fig. 83 Installation Position Of Lower Control Arm
Front Bushing
Fig. 84 Tools Assembled For Installation Of Front
Bushing
the Nut, Speci al Tool 69083 (Fi g. 84). Thi s wi l l pul l
the front bushi ng i nto the l ower control arm.
(5) Conti nue pul l i ng the bushi ng i nto the l ower
control arm unti l bushi ng i s seated squarel y agai nst
the l ower control arm and there i s no gap between
the bushi ng and the l ower control arm (Fi g. 85).
(6) I nstal l the l ower control arm on the front sus-
pensi on cradl e. Refer to Lower Control Arm i n the
Removal And I nstal l ati on Secti on i n thi s group of the
servi ce manual for the requi red procedure.
LOWER CONTROL ARM REAR BUSHING
REMOVE
(1) Remove the l ower control arm from the front
suspensi on cradl e. Refer to Lower Control Arm i n the
(2) Mount the l ower control arm i n a vi se without
usi ng excessi ve cl ampi ng force.
(3) Usi ng a sharp kni fe, (such as a razor) sl i t the
bushi ng l engthwi se (Fi g. 86) to al l ow i ts removal
from the l ower control arm (Fi g. 86).
(4) Remove the bushi ng from the l ower control
arm.
INSTALL
CAUTION: Do not apply grease or any other type of
lubricant other than the silicone lubricant specified
below to the control arm bushing.
(1) Appl y Mopar Si l i cone Spray Lube or an equi v-
al ent, to the hol e i n l ower control arm rear bushi ng.
Thi s wi l l ai d i n the i nstal l ati on of the bushi ng on the
l ower control arm.
(2) Wi th the l ower control arm hel d securel y i n a
vi se, i nstal l bushi ng on l ower control arm. I nstal l
bushi ng by pushi ng and rocki ng the bushi ng unti l i t
i s ful l y i nstal l ed on l ower control arm. Be sure when
bushi ng i s i nstal l ed i t i s past the upset on the end of
the l ower control arm (Fi g. 87).
(3) The rear bushi ng of the l ower control arm,
when correctl y i nstal l ed, i s to be posi ti oned on the
l ower control arm as shown i n (Fi g. 87).
STABILIZER BAR BUSHING
Disassembly/Assembly
(1) I f stabi l i zer bar to front suspensi on cradl e
bushi ngs requi re repl acement at ti me of i nspecti on,
i nstal l new bushi ngs before i nstal l i ng stabi l i zer bar.
Stabi l i zer bar bushi ngs are repl aced by openi ng the
sl i t on the bushi ngs and peel i ng them off the stabi -
l i zer bar. I nstal l new bushi ngs on stabi l i zer bar, by
spreadi ng bushi ng at sl i t and forci ng them on stabi -
l i zer bar.
Fig. 85 Correctly Installed Lower Control Arm
Bushing
Fig. 86 Slit Lower Control Arm Rear Bushing
Fig. 87 Correctly Installed Lower Control Arm
Bushing
NOTE: Bushings must be installed on stabilizer bar
so the square corner of the bushing will be down
and slit in bushing will be facing the rear of the
vehicle when the stabilizer is installed (Fig. 88).
SPECIFICATIONS
FRONT SUSPENSION FASTENER TORQUES
DESCRIPTION TORQUE
McPHERSON STRUT:
To Strut Tower
Attachi ng Nuts . . . . . . . . . . . .28 Nm (250 i n. l bs.)
Cl evi s Bracket To Steeri ng
Knuckl e . . . . . . . . . . . . . . . . . .88 Nm (65 ft. l bs.)
Pl us 1/4 Addi ti onal Turn
Strut Shaft Nut . . . . . . . . . . . . .100 Nm (75 ft. l bs.)
STEERING KNUCKLE:
Bal l Joi nt Stud To Steeri ng
Knuckl e Nut/Bol t . . . . . . . . .136 Nm (100 ft. l bs.)
Di sc Brake Cal i per Bol ts . . . . . . .22 Nm (16 ft. l bs.)
Wheel Stop . . . . . . . . . . . . . . . . . .95 Nm (70 ft. l bs.)
STEERING GEAR:
To Suspensi on Cradl e
Attachi ng Bol ts . . . . . . . . . . .183 Nm (135 ft. l bs.)
Ti e Rod End Adjusti ng
Sl eeve Nut . . . . . . . . . . . . . . . .75 Nm (55 ft. l bs.)
Ti e Rod End To Steeri ng
Knuckl e Nut . . . . . . . . . . . . . . .61 Nm (45 ft. l bs.)
FRONT SUSPENSION CRADLE:
To Body Attachi ng Bol ts . . . . . .163 Nm (120 ft. l bs.)
Lower Control Arm
Pi vot Bol t . . . . . . . . . . . . . . .185 Nm (137 ft. l bs.)
Lower Control Arm Rear
Bushi ng Retai ner Bol t . . . . . . .68 Nm (50 ft. l bs.)
Rei nforcement Pl ate
Attachi ng Bol ts M-12 . . . . . . .108 Nm (80 ft. l bs.)
Rei nforcement Pl ate
Attachi ng Bol ts M-14 . . . . . .166 Nm (123 ft. l bs.)
STABILIZER BAR:
Bushi ng Retai ner ToSuspensi on
Cradl e Attachi ng Bol ts . . . . . . .70 Nm (50 ft. l bs.)
Attachi ng Li nk Nuts . . . . . . . . . . .88 Nm (65 ft. l bs.)
HUB AND BEARING:
To Steeri ng Knuckl e Bol ts . . . . . .110 Nm (80 ft. l bs.)
Front Stub Axl e To Hub
Beari ng Nut . . . . . . . . . . . . .183 Nm (135 ft. l bs.)
Wheel Mounti ng
Lug Nut . . . . . . . . . . .110-135 Nm (85-115 ft. l bs.)
Fig. 88 Correctly Installed Stabilizer Bar To Cradle
Bushing
SPECIAL TOOLS
FRONT SUSPENSION
Installer Ball Joint 6758
Wrench Strut Rod Nut 6864
Remover Ball Joint 6919
Remover/Installer Control Arm Bushing 6908
Remover Tie Rod End MB991113
REAR SUSPENSION
INDEX
page page
GENERAL INFORMATION
REAR SUSPENSION . . . . . . . . . . . . . . . . . . . . . 38
REAR TRACK BAR . . . . . . . . . . . . . . . . . . . . . . . 39
REAR WHEEL ALIGNMENT . . . . . . . . . . . . . . . . 39
SHOCK ABSORBERS (REAR LOAD LEVELING) . 40
STABILIZER BAR . . . . . . . . . . . . . . . . . . . . . . . . 39
JOUNCE BUMPER . . . . . . . . . . . . . . . . . . . . . . . 46
LEAF SPRING FRONT MOUNT . . . . . . . . . . . . . 47
LEAF SPRING REAR MOUNT . . . . . . . . . . . . . . 47
REAR SPRINGS (AWD) . . . . . . . . . . . . . . . . . . . 43
REAR SPRINGS (FWD) . . . . . . . . . . . . . . . . . . . 40
REAR TRACK BAR . . . . . . . . . . . . . . . . . . . . . . . 45
SHOCK ABSORBER . . . . . . . . . . . . . . . . . . . . . . 45
STABILIZER BAR . . . . . . . . . . . . . . . . . . . . . . . . 46
TRACK BAR MOUNT . . . . . . . . . . . . . . . . . . . . . 45
SPECIFICATIONS
REAR SUSPENSION FASTENER TORQUES . . . 48
GENERAL INFORMATION
REAR SUSPENSION
The rear suspensi on desi gn on thi s vehi cl e uses
l eaf spri ngs and a tube and casti ng axl e (Fi g. 1) and
(Fi g. 2). I t i s desi gned to handl e the vari ous l oad
requi rements of the vehi cl e. The l eaf spri ngs used on
the rear suspensi on of thi s vehi cl e are of ei ther a
mono-l eaf or mul ti -l eaf desi gn.
The rear axl e used on front wheel dri ve appl i ca-
ti ons of thi s vehi cl e i s mounted to the rear l eaf
spri ngs usi ng i sol ator bushi ngs at the axl e mounti ng
brackets.
The rear axl e used on al l wheel dri ve appl i cati ons
of thi s vehi cl e i s al so mounted to the rear l eaf
spri ngs but does not use i sol ator bushi ngs between
the rear axl e and the l eaf spri ngs.
Fig. 1 Front Wheel Drive Rear Suspension
The rear suspensi on used on the front wheel dri ve
commerci al versi on of thi s vehi cl e i s uni que to thi s
appl i cati on. The rear axl e i s mounted to the rear l eaf
spri ngs as on the non-commerci al appl i cati on of thi s
vehi cl e but does not use any i sol ators between the
spri ng and the axl e. The l eaf spri ng used on the com-
merci al versi on of thi s vehi cl e i s a mul ti -l eaf spri ng
but i s a uni que desi gn for the commerci al appl i ca-
ti on.
The rear l eaf spri ng shackl e angl es provi de
i ncreasi ng suspensi on rates as the vehi cl e i s l oaded.
Thi s provi des a comfortabl e unl oaded ri de and al so
ampl e rear suspensi on travel when the vehi cl e i s
l oaded.
A new type of l oad-l evel i ng shock i s avai l abl e. The
sel f l evel i ng shock absorbers are a sel f-contai ned
vehi cl e l evel i ng system and shock absorber combi ned.
The shock absorbers are mounted at an angl e, paral -
l el to the spri ngs and forward at the top. Thi s desi gn
provi des greater stabi l i ty i n addi ti on to control l i ng
ri de moti on.
The rear wheel beari ngs used are si mi l ar to the
beari ngs used i n the front wheel s. The beari ngs are
permanentl y seal ed and requi re no mai ntenance. The
beari ng and hub are servi ced as an assembl y. For
servi ce procedures, refer to Group 5, Brakes.
REAR WHEEL ALIGNMENT
Al i gnment adjustment i s not requi red. The rear
axl e al i gnment setti ngs are preset at the factory and
therefore no al i gnment i s necessary.
REAR TRACK BAR
On front wheel dri ve appl i cati ons of thi s vehi cl e
that are equi pped wi th si ngl e l eaf rear spri ngs a
track bar (Fi g. 3) i s used on the rear axl e.
The track bar connects the rear axl e to the frame/
body of the vehi cl e. The track bar i s i sol ated from the
body of the vehi cl e by an i sl oator bushi ng l ocated i n
each end of the track bar.
The track bar (Fi g. 3) prevents excessi ve si de to
si de movement of the rear axl e. The track bar i s used
to keep the l ocati on of the axl e i n the correct posi ti on
for opti mum handl i ng and control of the vehi cl e.
STABILIZER BAR
The stabi l i zer bar (Fi g. 4) i nterconnects both si des
of the rear axl e and attaches to the rear frame rai l s
usi ng 2 rubber i sol ated l i nk arms.
Jounce and rebound movements affecti ng one
wheel are parti al l y transmi tted to the opposi te wheel
to reduce body rol l .
Fig. 2 All Wheel Drive Rear Suspension
Attachment to the rear axl e tube, and rear frame
rai l s i s through rubber-i sol ated bushi ngs. Al l parts
are servi ceabl e, and the stabi l i zer bar to axl e bush-
i ngs are spl i t for easy removal and i nstal l ati on. The
spl i t i n the bushi ng shoul d be posi ti oned up when
the stabi l i zer bar i s i nstal l ed on the vehi cl e.
The 2 rubber i sol ated l i nk arms are connected to
the rear frame rai l s by brackets. These brackets are
bol ted to the bottom of the frame rai l s.
SHOCK ABSORBERS (REAR LOAD LEVELING)
A new type of l oad-l evel i ng shock i s avai l abl e. The
sel f l evel i ng shock absorbers are a sel f-contai ned
vehi cl e l evel i ng system and shock absorber combi ned.
I t does not requi re an external compressor, hoses,
hei ght l evel i ng sensors, etc. I t uses road i nputs
(bumps, stops, starts, turns, accel erati on, decel era-
ti on, etc.) to acti vate pumpi ng, whi ch i s just the
extensi on and compressi on of the shock absorber. On
the outsi de, i t l ooks l i ke a l arger than normal shock
absorber. I nternal l y, i t consi sts of a hydraul i c pump
and gas-spri ng cushi on for l evel i ng, as wel l as the
normal shock absorbi ng mechani sm. Al l the hei ght
l evel i ng sensors, pump, etc., are contai ned i nsi de the
shocks. The shocks are mounted at an angl e, paral l el
to the spri ngs and forward at the top. Thi s desi gn
provi des greater stabi l i ty i n addi ti on to control l i ng
ri de moti on. These new l oad-l evel i ng shock absorbers
use l onger fasteners than the standard shock absorb-
ers, al though the fasteners are l onger, the torque
speci fi cati ons are the same.
REAR SPRINGS (FWD)
REMOVAL
(1) Rai se vehi cl e on frame contact hoi st to a com-
fortabl e worki ng posi ti on.
(2) Support axl e wi th a jack stand. Pad shoul d just
contact axl e.
(3) Begi n removal of the shock absorber l ower
mounti ng bol t (Fi g. 5).
Fig. 4 Stabilizer Bar
Fig. 3 Rear Track Bar
NOTE: If shock absorber bolt deflects upward dur-
ing removal, raise axle by adjusting support jack. If
shock absorber bolt deflects downward during
removal, lower axle by adjusting support jack (or by
pulling on axle).
(4) Usi ng 2 jack stands posi ti oned under the outer
ends of the axl e, rai se the axl e enough to remove the
wei ght of the axl e from the rear spri ngs.
(5) Loosen and remove the axl e pl ate bol ts from
the rear axl e (Fi g. 6).
(6) Remove the axl e pl ate from the rear axl e and
the l eaf spri ng (Fi g. 7).
(7) Usi ng the jack stands slowly l ower the rear
axl e, permi tti ng the rear spri ngs to hang free.
(8) Loosen and remove the 4 bol ts (Fi g. 8) from the
front mount of the l eaf spri ng.
(9) Loosen and remove the nuts from the spri ng
hanger (Fi g. 9) for the rear l eaf spri ng. Then remove
the hanger pl ate from the hanger and remove the
spri ng from the spri ng hanger (Fi g. 9).
Fig. 5 Rear Shock Mounting Bolt
Fig. 6 Axle Plate Bolts
Fig. 7 Axle Plate
Fig. 8 Leaf Spring Front Mount
Fig. 9 Rear Spring Hanger
(10) Remove the l eaf spri ng from the vehi cl e (Fi g.
10).
(11) Loosen and remove the pi vot bol t from the
front mount of the rear l eaf spri ng. (Fi g. 11).
FRONT BUSHING REPLACEMENT
(1) I nstal l l eaf spri ng i n a proper hol di ng fi xture.
(2) I nstal l l eaf spri ng press Speci al Tool C-4212F.
(3) I nstal l adapter Speci al Tool C-42123.
(4) Ti ghten l eaf spri ng press unti l bushi ng i s
extracted from l eaf spri ng.
(5) Remove l eaf spri ng press from l eaf spri ng.
(6) I nsert repl acement bushi ng i nto the l eaf spri ng
eye. Verify that the bushing flange is on the left
side of the leaf spring when leaf spring is in the
in vehicle installed position.
(9) Ti ghten l eaf spri ng press unti l bushi ng fl ange
bottoms sol i dl y agai nst l eaf spri ng eye.
(10) Remove l eaf spri ng press and adapter.
(11) Bend the bushi ng tabs so that they are con-
tacti ng the l eaf spri ng.
INSTALLATION
(1) Assembl e front spri ng mount to front of spri ng
eye and i nstal l pi vot bol t and nut. Do not ti ghten.
CAUTION: Pivot bolt must face inboard to prevent
structural damage during installation of spring.
(2) Rai se front of spri ng and i nstal l four hanger
bol ts, ti ghten to 61 Nm (45 ft. l bs.) torque.
(3) I nstal l rear of spri ng onto rear spri ng shackl e.
I nstal l shackl e pl ate. Do not ti ghten.
(4) Veri fy l ower l eaf spri ng i sol ator i s i n posi ti on.
(5) Rai se axl e i nto correct posi ti on on l eaf spri ng
wi th axl e centered under spri ng l ocator post (Fi g.
12).
(6) Veri fy that the l eaf spri ng i sol ator i s correctl y
posi ti oned i n the axl e pl ate.
(7) I nstal l axl e pl ate on the spri ng.
(8) I nstal l axl e pl ate bol ts. Ti ghten bol ts to 108
Nm (80 ft. l bs.) torque.
(9) I nstal l shock absorber bol ts. Do not ti ghten.
(10) Lower vehi cl e to fl oor so that the ful l wei ght
of vehi cl e i s supported by the ti res.
(11) Ti ghten component fasteners as fol l ows:
Front pi vot bol t156 Nm (115 ft. l bs.)
Shackl e nuts61 Nm (45 ft. l bs.)
Shock absorber bol ts101 Nm (75 ft. l bs.)
(12) I f the vehi cl e i s not equi pped wi th anti l ock
brakes, rai se vehi cl e and the connect the actuator for
the hei ght sensi ng proporti oni ng val ve on the rear
l eaf spri ng. Adjust the hei ght sensi ng proporti oni ng
val ve. Refer to the Adjustment Secti on i n thi s group
of the servi ce manual for the requi red adjustment
procedure.
Fig. 10 Leaf Spring Remove/Install
Fig. 12 Leaf Spring Locator Post
REAR SPRINGS (AWD)
REMOVE
(1) Rai se vehi cl e on frame contact hoi st to a com-
fortabl e worki ng posi ti on.
(2) Remove the dri veshaft from the si de of the
vehi cl e that requi res the removal of the l eaf spri ng.
Refer to Group 3 Dri vel i ne i n thi s servi ce manual for
the procedure coveri ng the removal of the rear dri ve-
shafts.
(3) Support axl e wi th a jack stand. Pad shoul d just
contact axl e.
NOTE: If shock absorber bolt deflects upward dur-
ing removal, raise axle by adjusting support jack. If
shock absorber bolt deflects downward during
removal, lower axle by adjusting support jack (or by
pulling on axle).
(4) Begi n removal of the shock absorber l ower
mounti ng bol t (Fi g. 13).
(5) Usi ng 2 jack stands posi ti oned under the outer
ends of the axl e, rai se the axl e enough to remove the
wei ght of the axl e from the rear spri ngs.
(6) Loosen and remove the axl e pl ate bol ts from
the rear axl e (Fi g. 14).
(7) Usi ng the jack stands slowly l ower the rear
axl e, permi tti ng the rear spri ngs to hang free.
(8) Loosen and remove the 4 bol ts (Fi g. 15) at the
front mount of the rear l eaf spri ng.
(9) Loosen and remove the 2 bol ts and the 2 nuts
from the spri ng hanger (Fi g. 16) for the rear l eaf
spri ng. Then remove the i nner hal f of the spri ng
hanger from the outer hal f hanger of the spri ng
hanger and the spri ng. (Fi g. 16).
(10) Remove the rear l eaf spri ng from the outer
hal f of the spri ng hanger
Fig. 13 Rear Shock Absorber Mounting Bolt
Fig. 14 Axle Plate Bolts
Fig. 16 Rear Spring Hanger
(11) Remove the l eaf spri ng from the vehi cl e (Fi g.
17).
(12) Loosen and remove the pi vot bol t from the
front mount of the rear l eaf spri ng. (Fi g. 18).
FRONT BUSHING REPLACEMENT
(1) I nstal l l eaf spri ng i n a proper hol di ng fi xture.
(4) Ti ghten l eaf spri ng press unti l bushi ng i s
extracted from l eaf spri ng.
(5) Remove l eaf spri ng press from l eaf spri ng.
(6) I nsert repl acement bushi ng i nto the l eaf spri ng
eye. Veri fy that the bushi ng fl ange i s on the outboard
si de of the l eaf spri ng.
(9) Ti ghten l eaf spri ng press unti l bushi ng fl ange
bottoms sol i dl y agai nst l eaf spri ng eye.
(10) Remove l eaf spri ng press and adapter.
(11) Bend the tabs on the bushi ng unti l they are
contacti ng the l eaf spri ng.
INSTALL
CAUTION: Pivot bolt must face inboard to prevent
structural damage during installation of spring.
(1) I nstal l the front of the rear l eaf spri ng i nto the
spri ng mount (Fi g. 18). I nstal l the pi vot bol t and nut.
Do not tighten the pivot bolt at this time.
(2) Posi ti on the front spri ng mount for the rear
l eaf spri ng agai nst the fl oor pan of the vehi cl e.
I nstal l the 4 mounti ng bol ts for the spri ng mount.
Ti ghten the 4 mounti ng bol ts to a torque of 61 Nm
(45 ft. l bs.).
(3) I nstal l the rear of the l eaf spri ng onto the outer
hal f of the rear hanger. I nstal l the i nner hal f of the
rear hanger. I nstal l the nut and bol ts on the rear
hanger but do not tighten at this time.
(4) Rai se axl e assembl y i nto correct posi ti on wi th
axl e centered under spri ng l ocator post.
(5) I nstal l axl e pl ate bol ts. Ti ghten bol ts to 108
(6) I nstal l shock absorber bol ts. Do not ti ghten.
(7) Lower vehi cl e to fl oor and wi th ful l wei ght of
vehi cl e on wheel s. Ti ghten component fasteners as
fol l ows:
CAUTION: The following sequence must be fol-
lowed when tightening the pin nuts on the rear
hanger for the rear leaf spring. First the hanger pin
nuts must be tightened to the specified torque
shown below. Then tighten the retaining bolts for
the inner to outer half of the spring hanger to the
torque specification listed below. This sequence
must be followed to properly seat the bushings into
the springs and to avoid bending the spring hanger.
Front pi vot bol t-156 Nm (115 ft. l bs.)
Rear spri ng hanger pi n nuts-61 Nm (45 ft. l bs.)
Rear spri ng hanger i nner to outer hal f retai ni ng
bol ts-61 Nm (45 ft. l bs.)
Shock absorber upper mounti ng bol t-115 Nm
(85 ft. l bs.)
Shock absorber l ower mounti ng bol t-108 Nm (80
ft. l bs.)
(8) I f the vehi cl e i s not equi pped wi th anti l ock
brakes, rai se vehi cl e and connect the actuator for the
hei ght sensi ng proporti oni ng val ve on the rear l eaf
spri ng. Adjust the hei ght sensi ng proporti oni ng
val ve. Refer to the Adjustment Secti on i n thi s group
of the servi ce manual for the requi red adjustment
procedure.
Fig. 17 Leaf Spring Remove/Install
SHOCK ABSORBER
REMOVE/INSTALL
(1) Rai se vehi cl e. Vehi cl e i s to be rai sed and sup-
ported on jackstands or on a frame contact type
hoi st. See Hoi sti ng i n the Lubri cati on And Mai nte-
nance secti on of thi s servi ce manual .
(2) Support the rear axl e of the vehi cl e usi ng 2
jackstands posi ti oned at the outer ends of the axl e.
NOTE: If the shock absorber lower mounting bolt
deflects upward during removal, raise axle by
adjusting the support jack. If the lower shock
absorber bolt deflects downward during removal,
lower the axle by adjusting the support jack.
(3) Remove the shock absorber l ower mounti ng
bol t.
(4) Whi l e hol di ng shock absorber, remove the
shock absorber upper mounti ng bol t.
(5) To i nstal l the shock absorber use the reverse
sequence of i ts removal .
(6) Lower the vehi cl e to the ground so the ful l
wei ght of the vehi cl e i s supported by the suspensi on.
(7) Ti ghten the upper and l ower shock absorber
mounti ng bol t to thei r speci fi ed torques.
REAR TRACK BAR
REMOVE
(1) Remove the nut and bol t mounti ng the track
bar to the rear axl e (Fi g. 19).
(2) Remove the nut and bol t attachi ng the track
bar to the track bar mount on the body of the vehi cl e.
Remove the track bar from the track bar mount.
INSTALL
(1) I nstal l the track bar fi rst i nto the body mount
for the track bar (Fi g. 20). I nstal l the track bar bol t
wi th the head of the bol t faci ng toward the rear of
the vehi cl e (Fi g. 21). Do not ti ghten.
(2) I nstal l the track bar i nto i ts mounti ng bracket
on the rear axl e (Fi g. 19). I nstal l the track bar bol t
wi th the head of the bol t faci ng toward the rear of
the vehi cl e. Do not ti ghten.
(3) Lower the vehi cl e to the ground unti l the ful l
wei ght of the vehi cl e i s supported by the wheel s.
Ti ghten both track bar attachi ng bol ts to a torque of
95 Nm (70 ft. l bs.).
TRACK BAR MOUNT
REMOVE
(1) Remove the track bar from the track bar
mount.
(2) Remove the three bol ts attachi ng the track bar
mount to the body (Fi g. 22).
Fig. 19 Track Bar Mounting To Axle
Fig. 20 Track Bar Installation
Fig. 21 Track Bar Bolt Installation
INSTALLATION
(1) For i nstal l ati on, reverse removal procedure.
Ti ghten bol ts to 61 Nm (45 ft. l bs.).
STABILIZER BAR
REMOVAL
ported on jack stands or on a frame contact type
hoi st. See Hoi sti ng i n the Lubri cati on and Mai nte-
(2) Remove the 2 l ower bol ts whi ch hol d the stabi -
l i zer bar to the l i nk arm on each si de of the vehi cl e.
(3) Loosen but do not ful l y remove the four bol ts
that attach the stabi l i zer bar bushi ng retai ners to
the rear axl e brackets.
(4) Whi l e hol di ng the stabi l i zer bar i n pl ace. Ful l y
remove the 4 bol ts l oosened i n step 3.
(5) Remove the stabi l i zer bar from the vehi cl e.
(6) I f the l i nk arms need to be servi ced, remove
the upper l i nk arm to bracket bol t. Then remove l i nk
arm from frame rai l attachi ng bracket.
INSPECTION
I nspect for broken or di storted cl amps, retai ners,
and bushi ngs. I f bushi ng repl acement i s requi red, the
stabi l i zer bar to axl e bushi ngs can be removed from
the stabi l i zer bar by openi ng the spl i t.
INSTALLATION
(1) I nstal l the l i nk arms onto the frame rai l brack-
ets. DO NOT TI GHTEN.
(2) Posi ti on the axl e to stabi l i zer bar bushi ngs on
the stabi l i zer bar wi th the sl i t i n the bushi ngs faci ng
up.
(3) Li ft the stabi l i zer bar onto the rear axl e and
i nstal l the retai ners and the four mounti ng bol ts. DO
NOT TI GHTEN.
(4) I nstal l the two l ower l i nk arm bol ts on the sta-
bi l i zer bar. DO NOT TI GHTEN.
(5) Lower the vehi cl e so that the ful l wei ght of the
vehi cl e i s on al l four ti res. Wi th the vehi cl e at i ts
curb hei ght, ti ghten al l attachi ng bol ts to the torques
l i sted bel ow.
Stabi l i zer bar bushi ng to axl e bracket bol ts 61
Nm (45 ft. l bs.)
Li nk arm to frame rai l bracket 61 Nm (45 ft.
l bs.)
Stabi l i zer bar to l i nk arm 61 Nm (45 ft. l bs.)
Frame rai l bracket to frame rai l 61 Nm (45 ft.
l bs.)
JOUNCE BUMPER
There are two types of jounce bumpers avai l abl e
dependi ng on whi ch suspensi on opti on the vehi cl e i s
equi pped wi th.
REMOVAL-STANDARD
The jounce bumper i s servi ced as an assembl y. The
jounce bumper mounts to the frame rai l at a wel d
nut l ocated on the frame rai l (Fi g. 23).
(1) Usi ng the proper tool , remove the bol t attach-
i ng the jounce bumper to frame rai l .
(2) Remove the jounce bumper from the frame rai l .
INSTALLATION-STANDARD
(1) For i nstal l ati on, reverse the removal procedure.
Ti ghten the jounce bumper mounti ng bol t to a torque
of 33 Nm (290 i n. l bs.).
Fig. 22 Track Bar Mount
Fig. 23 Jounce Bumper-Standard
REMOVAL-HEAVY DUTY
The jounce bumpers are servi ced as an assembl y.
The jounce bumpers screw i nto a wel d nut l ocated i n
the frame rai l (Fi g. 24).
(1) Usi ng sl i p-joi nt pl i ers grasp the base of the
jounce bumper. Turn the base countercl ockwi se (Fi g.
25).
(2) Remove the jounce bumper from the frame rai l .
INSTALLATION-HEAVY DUTY
(1) For i nstal l ati on, reverse the removal procedure.
Ti ghten the jounce bumper to a torque of 33 Nm
(290 i n. l bs.).
LEAF SPRING FRONT MOUNT
REMOVE
(1) Loosen the pi vot bol t attachi ng the front of the
l eaf spri ng to the spri ng mount (Fi g. 26).
(2) I nstal l a jackstand under the si de of the axl e
havi ng the l eaf spri ng mount removed. Usi ng the
jackstand support the wei ght of the axl e and l eaf
spri ng.
(3) Remove the l ower mounti ng bol t from the
shock absorber.
(4) Remove the bol ts attachi ng the l eaf spri ng
front mount (Fi g. 26) to the body of the vehi cl e.
(5) Lower the l eaf spri ng and remove the front
mount from the spri ng.
INSTALLATION
(1) For i nstal l ati on, reverse removal procedure. Do
not ti ghten front through bol t ful l y unti l vehi cl e i s
l owered and the ful l vehi cl e wei ght i s appl i ed to the
rear wheel s. Ti ghten l eaf spri ng front mount bol ts to
61 Nm (45 ft. l bs.). Ti ghten l eaf spri ng front through
bol t to 156 Nm (115 ft. l bs.).
LEAF SPRING REAR MOUNT
REMOVE
(1) Remove the attachi ng nuts and bol ts from the
l eaf spri ng rear shackl e (Fi g. 27) and (Fi g. 28).
Fig. 24 Jounce Bumper-Heavy Duty
Fig. 25 Bumper Replacement
Fig. 27 Leaf Spring Shackle Nuts (FWD)
(2) I nstal l a jackstand under the si de of the axl e
havi ng the l eaf spri ng mount removed. Usi ng the
jackstand, support the wei ght of the axl e and l eaf
spri ng.
(3) Remove the l ower mounti ng bol t from the
shock absorber.
(4) Remove the bol ts attachi ng the l eaf spri ng rear
mount to the body of the vehi cl e (Fi g. 29).
(5) Lower the jackstand and the rear of the l eaf
spri ng. Remove the shackl e from the l eaf spri ng
bushi ng.
INSTALL
CAUTION: The following sequence must be fol-
lowed when tightening the pin nuts on the rear
hanger for the rear leaf spring. First the hanger pin
nuts must be tightened to the specified torque.
Then tighten the retaining bolts for the inner to
outer half of the spring hanger to the specified
torque. This sequence must be followed to avoid
bending the spring hanger.
(1) For i nstal l ati on, reverse removal procedure. Do
not ti ghten rear spri ng shackl e nuts ful l y unti l vehi -
cl e i s l owered and the ful l vehi cl e wei ght i s appl i ed
to the rear wheel s. Ti ghten rear spri ng mount bol ts
to 61 Nm (45 ft. l bs.). Ti ghten shackl e nuts to 61
Nm (45 ft. l bs.).
SPECIFICATIONS
REAR SUSPENSION FASTENER TORQUES
DESCRIPTION TORQUE
SHOCK ABSORBER MOUNTING BOLTS:
Standard Shock Absorber . . . . . .101 Nm (75 ft. l bs.)
Sel f Load Level i ng Shock
Absorber . . . . . . . . . . . . . . . . .101 Nm (75 ft. l bs.)
J OUNCE BUMPER:
To Frame Rai l . . . . . . . . . . . . . .33 Nm (290 i n. l bs.)
TRACK BAR:
To Axl e And Mounti ng
Bracket Pi vot Bol t . . . . . . . . . .95 Nm (70 ft. l bs.)
Bracket To Body Attachi ng . . . . . .61 Nm (45 ft. l bs.)
LEAF SPRING:
Spri ng Pl ate To Axl e
Attachi ng Bol ts . . . . . . . . . . . .108 Nm (80 ft. l bs.)
Rear Mount To Body Bol ts . . . . . .61 Nm (45 ft. l bs.)
Front Mount To Body Bol ts. . . . . .61 Nm (45 ft. l bs.)
To Front Hanger
Mounti ng Nut . . . . . . . . . . . .156 Nm (115 ft. l bs.)
Shackl e Pl ate Nuts . . . . . . . . . . . .61 Nm (45 ft. l bs.)
STABILIZER BAR:
Bushi ng Retai ner To Axl e
Attachi ng Bol ts . . . . . . . . . . . . .61 Nm (45 ft. l bs.)
Attachi ng Li nk Nuts . . . . . . . . . . .61 Nm (45 ft. l bs.)
Frame Rai l Bracket
Mounti ng Bol ts . . . . . . . . . . . . .61 Nm (45 ft. l bs.)
Li nk Arm To Frame
Rai l Bracket . . . . . . . . . . . . . . .61 Nm (45 ft. l bs.)
HUB AND BEARING:
To Axl e Mounti ng Bol ts. . . . . . . .129 Nm (95 ft. l bs.)
Stub Axl e Nut . . . . . . . . . . . . . .224 Nm (180 ft. l bs.)
Wheel Mounti ng
Lug Nut . . . . . . . . . . .110-135 Nm (85-115 ft. l bs.)
Fig. 28 Leaf Spring Shackle Nuts/Bolts (AWD)
Fig. 29 Rear Spring Mount
SUSPENSION
CONTENTS
page
SPECIFICATIONS
ALIGNMENT SPECIFICATIONS . . . . . . . . . . . . . 1
SPECIFICATIONS
ALIGNMENT SPECIFICATIONS
Al l al i gnment speci fi cati ons are to be checked and
adjusted wi th the vehi cl e at i ts correct ri de hei ght.
Refer to the ri de hei ght speci fi cati ons l i sted i n the
fol l owi ng al i gnment speci fi cati ons chart.
* Camber is adjustable using the Mopar Cam-
ber Adjustment Service Kit. Refer to the Mopar
Parts Catalog for the required service kit part
number.
** Caster is not adjustable. If found to be out
of specification check for proper ride heights
and damaged/worn out suspension components
and replace as necessary.
*** Toe-In is positive.
**** Toe, Camber and thrust angle are not
adjustable. If found to be out of specification
check for proper ride heights and damaged/
worn out suspension components and replace
as necessary.
***** When Measuring ride heights: 1) Ensure
that the tire pressures are correct. 2) J ounce
the vehicle at the bumper several times and
release at the bottom of the stroke. 3) Measure
from the ground to the outboard, lower, center
section of the fender wheel well opening. Ride
heights are not adjustable. If found to be out of
specification check for damaged and/or worn
out suspension components and replace as nec-
essary.
NS/GS SUSPENSION 2 - 1
ALIGNMENT ANGLE TIRE SIZES TIRE SIZES
ALTERNATIVE
FUELS
P205/75/R14 P205/75/R15 C.N.G.
P215/65/R15 P215/65/R16 ELECTRIC
* FRONT INDIVIDUAL CAMBER IN
DEGREES............................................
+0.15+or- 0.40 +0.05+or- 0.40 +0.15+or- 0.40
Front Side To Side Camber Difference Not
To Exceed...................
0.00- 0.50MAX 0.00- 0.50MAX 0.00- 0.50MAX
** FRONT INDIVIDUAL CASTER IN
DEGREES............................................
+1.40+ or - 1.00 +1.40+ or - 1.00 +1.40+or- 1.00
Front Side To Side Caster Difference Not To
Exceed.....................................
0.00- 1.00MAX 0.00- 1.00MAX 0.00- 1.00MAX
*** FRONT INDIVIDUAL TOE RIGHT/
LEFT.........................................
+0.05+or- 0.10 +0.05+or- 0.10 +0.05+or- 0.10
FRONT TOTAL
TOE....................................................
+0.10+or- 0.20 +0.10+or- 0.20 +0.10+or- 0.20
FRONT SIDE TO SIDE TOE
DIFFERENTIAL.....................................
0.00- 0.06MAX 0.00- 0.06MAX 0.00- 0.06MAX
****REAR INDIVIDUAL CAMBER IN
DEGREES............................................
+0.00+or- 0.25 +0.00+or- 0.25 -0.10+or- 0.25
REAR INDIVIDUAL TOE RIGHT/
LEFT........................................
0.00+or- 0.40 0.00+or- 0.40 0.00+or- 0.40
**** REAR TOTAL TOE.....................
TOE OUT: When Backed On Alignment Rack
Is TOE In When Driving
0.00+or- 0.40 0.00+or- 0.40 0.00+or- 0.40
****REAR THRUST ANGLE................ 0.00+or- 0.30 0.00+or- 0.30 0.00+or- 0.30
STEERING WHEEL ANGLE................ 0.00+or- 2.50 0.00+or- 2.50 0.00+or- 2.50
FRONT RIDE HEIGHT (MEASURED AT
TOP OF FENDER WHEEL
OPENING)............................................
747.5 mm
+or-10.0mm
753.5 mm
+or-10.0mm
783.5 mm
+or-10.0mm
FRONT RIDE HEIGHT SIDE TO SIDE
DIFFERENTIAL.....................................
0.0 mm 12.5 mm
MAX
0.0 mm 12.5 mm
MAX
0.0 mm 12.5 mm
MAX
*****REAR RIDE HEIGHT (MEASURED AT
TOP OF FENDER WHEEL
OPENING)............................................
766.0 mm
+or-10.0mm
772.0 mm
+or-10.0mm
802.5 mm
+or-10.0mm
*****REAR RIDE HEIGHT SIDE TO SIDE
DIFFERENTIAL.....................................
0.0 mm 12.5 mm
MAX
0.0 mm 12.5 mm
MAX
0.0 mm 12.5 mm
MAX
2 - 2 SUSPENSION NS/GS
BRAKES
CONTENTS
page page
ANTILOCK BRAKE SYSTEM
TEVES MARK-20 . . . . . . . . . . . . . . . . . . . . . . . 85
BASE BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . 3
GENERAL INFORMATION
INDEX
page page
GENERAL INFORMATION
BASE BRAKE SYSTEM COMPONENT
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 1
GENERAL VEHICLE SERVICE CAUTIONS . . . . . . 1
GENERAL INFORMATION
GENERAL VEHICLE SERVICE CAUTIONS
CAUTION: At no time when servicing a vehicle, can a
sheet metal screw, bolt or other metal fastener be
installed in the shock tower to take the place of an
original plastic clip. Also, NO holes can be drilled into
the front shock tower in the area shown in (Fig. 1), for
the installation of any metal fasteners into the shock
tower. Because of the minimum clearance in this area
(Fig. 1), installation of metal fasteners could damage
the coil spring coating and lead to a corrosion failure
of the spring. If a plastic clip is missing, or is lost or
broken during servicing a vehicle, replace only with
the equivalent part listed in the Mopar parts catalog.
CAUTION: Only the recommended jacking or hoisting
positions for this vehicle are to be used whenever it is
necessary to lift a vehicle. Failure to raise a vehicle
from the recommended locations could result in lifting
a vehicle by the hydraulic control unit mounting
bracket. Lifting a vehicle by the hydraulic control unit
mounting bracket will result in damage to the mount-
ing bracket and the hydraulic control unit.
BASE BRAKE SYSTEM COMPONENT DESCRIPTION
The standard brake system on thi s vehi cl e consi sts
of the fol l owi ng components:
Doubl e pi n fl oati ng cal i per di sc front brakes.
Doubl e pi n fl oati ng cal i per rear di sc brakes on
al l wheel dri ve appl i cati ons.
Rear automati c adjusti ng drum brakes.
Master cyl i nder wi th brake fl ui d l evel sensor.
Vacuum booster.
Hei ght sensi ng proporti oni ng val ve (non-anti l ock
brake appl i cati ons)
Non-hei ght sensi ng proporti oni ng val ve (anti l ock
brake appl i cati ons)
The brakes hydraul i c system on both non-anti l ock
and anti l ock brake systems i s di agonal l y spl i t (Fi g. 2)
(Fi g. 3). A di agonal l y spl i t brake system means the
l eft front and ri ght rear brakes on one hydraul i c sys-
tem and the ri ght front and l eft rear on the other.
Fig. 1 Shock Tower To Spring Minimum Clearance
Area
NS BRAKES 5 - 1
Fig. 2 Non-Antilock Brakes Hydraulic Brake Tube Routing And Fitting Locations
Fig. 3 Antilock Brakes/Traction Control Hydraulic Brake Tube Routing And Fitting Locations
5 - 2 BRAKES NS
BASE BRAKE SYSTEM
INDEX
page page
CHASSIS TUBES AND HOSES . . . . . . . . . . . . . . 7
FRONT DISC BRAKE SYSTEM . . . . . . . . . . . . . . 4
HUB/BEARING REAR WHEEL . . . . . . . . . . . . . . . 9
MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . 7
PARKING BRAKE SYSTEM OPERATION . . . . . . . 5
POWER BRAKE VACUUM BOOSTER
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
PROPORTIONING VALVES . . . . . . . . . . . . . . . . . 5
REAR DISC BRAKES . . . . . . . . . . . . . . . . . . . . . . 5
REAR DRUM BRAKES . . . . . . . . . . . . . . . . . . . . . 5
RED BRAKE WARNING LAMP OPERATION . . . . . 8
STOP LAMP SWITCH . . . . . . . . . . . . . . . . . . . . . . 9
ADJUSTER REAR DRUM BRAKE
(AUTOMATIC) . . . . . . . . . . . . . . . . . . . . . . . . . 14
BRAKE FLUID CONTAMINATION . . . . . . . . . . . . 19
BRAKE ROTOR . . . . . . . . . . . . . . . . . . . . . . . . . 14
BRAKE SYSTEM BASIC DIAGNOSIS GUIDE . . . . 9
BRAKE SYSTEM DIAGNOSIS CHARTS . . . . . . . 10
PROPORTIONING VALVES . . . . . . . . . . . . . . . . 16
RED BRAKE WARNING LAMP TEST . . . . . . . . . 19
STOP LAMP SWITCH TEST PROCEDURE . . . . . 19
TRACTION CONTROL LAMP TEST . . . . . . . . . . 19
SERVICE PROCEDURES
BLEEDING BASE BRAKE
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . 20
BRAKE DRUM MACHINING . . . . . . . . . . . . . . . . 24
BRAKE TUBE REPAIR PROCEDURE . . . . . . . . . 24
MASTER CYLINDER BLEEDING
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . 22
MASTER CYLINDER FLUID LEVEL CHECK . . . . 20
PARK BRAKE AUTO ADJUSTER
MECHANISM RELEASE . . . . . . . . . . . . . . . . . 26
ROTOR MACHINING (FRONT/REAR) . . . . . . . . . 22
BRAKE SUPPORT PLATE (REAR DRUM
BRAKES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
FRONT DISC BRAKE CALIPER . . . . . . . . . . . . . 27
FRONT DISC BRAKE PADS . . . . . . . . . . . . . . . . 30
FRONT PARK BRAKE CABLE . . . . . . . . . . . . . . 65
HUB/BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . 40
HYDRAULIC BRAKE TUBES AND HOSES . . . . . 58
INTERMEDIATE PARK BRAKE CABLE . . . . . . . 66
JUNCTION BLOCK . . . . . . . . . . . . . . . . . . . . . . . 55
LEFT REAR PARK BRAKE CABLE . . . . . . . . . . . 67
MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . 44
PARK BRAKE PEDAL MECHANISM . . . . . . . . . . 58
PARK BRAKE SHOES (WITH REAR DISC
BRAKES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
PROPORTIONING VALVE (W/ABS BRAKES) . . . 56
PROPORTIONING VALVE
(W/O ABS BRAKES) . . . . . . . . . . . . . . . . . . . . 57
REAR BRAKE DRUM . . . . . . . . . . . . . . . . . . . . . 33
REAR BRAKE WHEEL CYLINDER . . . . . . . . . . . 39
REAR DISC BRAKE CALIPER . . . . . . . . . . . . . . 28
REAR DISC BRAKE SHOES . . . . . . . . . . . . . . . . 31
REAR DRUM BRAKE SHOES . . . . . . . . . . . . . . . 34
RIGHT REAR PARK BRAKE CABLE . . . . . . . . . 66
STOP LAMP SWITCH . . . . . . . . . . . . . . . . . . . . . 69
VACUUM BOOSTER 2.4 LITER ENGINE . . . . . . 47
VACUUM BOOSTER 3.0 LITER ENGINE . . . . . . 49
VACUUM BOOSTER 3.3/3.8 LITER ENGINE . . . . 52
WHEEL AND TIRE INSTALLATION . . . . . . . . . . . 27
FRONT DISC BRAKE CALIPER . . . . . . . . . . . . . 71
MASTER CYLINDER BRAKE FLUID LEVEL
SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
MASTER CYLINDER FLUID RESERVOIR
FILL TUBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
MASTER CYLINDER FLUID RESERVOIR . . . . . . 70
MASTER CYLINDER TO POWER BRAKE
BOOSTER VACUUM SEAL . . . . . . . . . . . . . . . 69
WHEEL CYLINDER REAR DRUM BRAKE . . . . . . 76
CLEANING AND INSPECTION
BRAKE HOSE AND BRAKE LINES
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 78
FRONT DISC BRAKE PAD LINING
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 76
REAR DISC BRAKES . . . . . . . . . . . . . . . . . . . . . 76
REAR DRUM BRAKE SHOE LINING
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 77
REAR DRUM BRAKE WHEEL CYLINDER . . . . . . 78
REAR WHEEL HUB AND BEARING
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
ADJUSTMENTS
PARK BRAKE CABLE ADJUSTMENT . . . . . . . . . 81
PARK BRAKE SHOES (WITH REAR DISC
BRAKES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
PROPORTIONING VALVE
(HEIGHT SENSING) . . . . . . . . . . . . . . . . . . . . 81
REAR DRUM BRAKE SHOE ADJUSTMENT . . . . 79
STOP LAMP SWITCH . . . . . . . . . . . . . . . . . . . . . 78
SPECIFICATIONS
BRAKE ACTUATION SYSTEM . . . . . . . . . . . . . . 83
BRAKE FASTENER TORQUE
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . 83
NS BRAKES 5 - 3
BRAKE FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . 82
VEHICLE BRAKE SYSTEM COMPONENT
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . 82
SPECIAL TOOLS
BASE BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . 84
FRONT DISC BRAKE SYSTEM
The si ngl e pi ston, fl oati ng cal i per di sc brake
assembl y (Fi g. 1) and (Fi g. 2) consi sts of:
The dri vi ng hub.
Braki ng di sc (rotor).
Cal i per assembl y.
Shoes and l i ni ngs.
The doubl e pi n Kel sey-Hayes cal i per i s mounted
di rectl y to the steeri ng knuckl e, usi ng bushi ngs,
sl eeves, and 2 cal i per gui de pi n bol ts whi ch thread
di rectl y i nto the steeri ng knuckl e (Fi g. 3).
The two machi ned abutments on the steeri ng
knuckl e, posi ti on and al i gn the cal i per fore and aft.
The gui de pi n bol ts, sl eeves, and bushi ngs control the
si de to si de movement of the cal i per. The pi ston seal
i s desi gned to assi st i n mai ntai ni ng the proper brake
shoe to rotor cl earance.
Al l the front brake forces generated duri ng braki ng
of the vehi cl e are taken up di rectl y by the steeri ng
knuckl es of the vehi cl e.
Fig. 2 Front Disc Brake Caliper Assembly (Exploded View)
Fig. 1 Front Disc Brake System Components
Fig. 3 Disc Brake Caliper Mounting To Steering
Knuckle
5 - 4 BRAKES NS
The cal i per i s a one pi ece casti ng wi th the i nboard
si de contai ni ng a si ngl e pi ston cyl i nder bore.
The phenol i c pi ston i s 60 mm (2.36 i nch) i n di am-
eter.
A square cut rubber pi ston seal i s l ocated i n a
machi ned groove i n the cyl i nder bore. I t provi des a
hydraul i c seal between the pi ston and the cyl i nder
wal l (Fi g. 4).
The mol ded rubber dust boot mounts i n a counter
bore of the cyl i nder bore openi ng and i n a groove
whi ch i s machi ned i n the outer surface of the pi ston
(Fi g. 4). Thi s prevents contami nati on of the pi ston
and the bore area.
As l i ni ng wears, reservoi r l evel wi l l go down. I f
fl ui d has been added, reservoi r overfl ow may occur
when the pi ston i s pushed back i nto the new l i ni ng
posi ti on. Overfl owi ng can be avoi ded by removi ng a
smal l amount of fl ui d from the master cyl i nder res-
ervoi r.
REAR DRUM BRAKES
The rear wheel drum brakes are a two shoe, i nter-
nal expandi ng type wi th an automati c adjuster screw.
The automati c adjuster screw i s actuated each ti me
the brakes are appl i ed. The automati c adjuster screw
i s l ocated di rectl y bel ow the wheel cyl i nder.
REAR DISC BRAKES
The rear di sc brakes are si mi l ar to front di sc
brakes, however, there are several di sti ncti ve fea-
tures that requi re di fferent servi ce procedures. The
si ngl e pi ston, fl oati ng cal i per rear di sc brake system
i ncl udes a hub and beari ng assembl y, adapter, rotor,
cal i per, and brake shoes. The parki ng brake system
on vehi cl es equi pped wi th rear di sc brakes, consi sts
of a smal l duo-servo drum brake mounted to the cal -
i per adapter. The drum brake shoes expand out
agai nst a braki ng surface (hat secti on) on the i nsi de
area of the rotor.
Thi s vehi cl e i s equi pped wi th a cal i per havi ng a 42
mm (1.65 i n.) pi ston and uses a 15 i nch sol i d non-
vented rotor.
The di sc brake cal i per fl oats on rubber bushi ngs
usi ng threaded gui de pi n bol ts whi ch are attached to
the back si de of the adapter.
The adapter and rotor shi el d are mounted to the
rear axl e. The adapter i s used to mount the brake
shoes and actuati ng cabl es for the parki ng brake sys-
tem. The adapter i s al so used to mount the rear cal -
i per. The adapter has two machi ned abutments
whi ch are used to posi ti on and al i gn the cal i per and
brake shoes for movement i nboard and outboard (Fi g.
5).
PARKING BRAKE SYSTEM OPERATION
The rear wheel servi ce brakes al so act as parki ng
brakes. The brake shoes are mechani cal l y operated
by an i nternal l ever and strut connected to a fl exi bl e
steel cabl e. The rear cabl es and i ntermedi ate cabl e
are connected to the front cabl e by an equal i zer. The
front cabl e extends to the parki ng brake foot pedal
assembl y.
PROPORTIONING VALVES
FIXED PROPORTIONING VALVE
The hydraul i c brake system on al l vehi cl es i s di ag-
onal l y spl i t. Thi s means that the l eft front and ri ght
rear brakes are on one hydraul i c ci rcui t wi th the
ri ght front and l eft rear brakes on the other hydrau-
l i c ci rcui t.
On vehi cl es equi pped wi th ABS brakes, the brake
systems hydraul i c control uni t (HCU) i s mounted to
the front suspensi on crossmember on the dri vers
si de of the vehi cl e. The (HCU) acts as the hydraul i c
system juncti on bl ock, di agonal l y spl i tti ng the brakes
hydraul i c system.
Al l vehi cl es equi pped wi th ABS brakes use 2 fi xed
proporti oni ng val ves. The fi xed proporti oni ng val ves
are mounted i n a common bracket on the l eft frame
rai l at the rear of the vehi cl e (Fi g. 6).
Fig. 4 Caliper Piston Seal Function For Automatic
Adjustment
Fig. 5 Rear Disc Brake Components
NS BRAKES 5 - 5
FIXED PROPORTIONING VALVE OPERATION
The fi xed proporti oni ng val ve i s made out of al umi -
num and has an i ntegral mounti ng bracket. The
fi xed proporti oni ng val ve i s non-servi ceabl e compo-
nent and must be repl aced as an assembl y i f found to
be functi oni ng i mproperl y.
The fi xed proporti oni ng val ve i s mounted to the
bottom of the l eft rear frame rai l , just forward of the
rear shock absorber to frame rai l mounti ng l ocati on
(Fi g. 6). The proporti oni ng val ve has 2 i nl et ports for
brake fl ui d comi ng from the ABS modul ator, and 2
outl et ports for brake fl ui d goi ng to the rear wheel
brakes.
The fi xed proporti oni ng val ve operates by al l owi ng
ful l hydraul i c pressure to the rear brakes up to a set
poi nt, cal l ed the val ves spl i t poi nt. Beyond thi s spl i t
poi nt the proporti oni ng val ve reduces the amount of
hydraul i c pressure to the rear brakes accordi ng to a
certai n rati o.
Thus, on l i ght brake pedal appl i cati ons the propor-
ti oni ng val ve al l ows approxi matel y equal brake
hydraul i c pressure to be suppl i ed to both the front
and rear brakes. On heavi er brake pedal appl i cati ons
though, the proporti oni ng val ve wi l l control hydraul i c
pressure to the rear brakes, so that hydraul i c pres-
sure at the rear brakes wi l l be l ower than that at the
front brakes. Thi s control l ed hydraul i c pressure to
the rear brakes prevents excessi ve rear wheel ABS
cycl i ng duri ng moderate stops.
HEIGHT SENSING PROPORTIONING VALVE
CAUTION: The use of after-market load leveling or
load capacity increasing devices on this vehicle are
prohibited. Using air shock absorbers or helper
springs on this vehicle will cause the height sens-
ing proportioning valve to inappropriately reduce
the hydraulic pressure to the rear brakes. This inap-
propriate reduction in hydraulic pressure potentially
could result in increased stopping distance of the
vehicle.
On vehi cl es not equi pped wi th ABS brakes, the
brake systems hydraul i c control uni t (HCU) i s
repl aced by a juncti on bl ock (Fi g. 7). The juncti on
bl ock i s made of al umi num and i s mounted to the
front suspensi on crossmember on the dri vers si de of
the vehi cl e i n the same l ocati on as the (HCU) on an
ABS equi pped vehi cl e. The juncti on bl ock i s perma-
nentl y attached to i ts mounti ng bracket and must be
repl aced as an assembl y wi th i ts mounti ng bracket.
The juncti on bl ock i s used for di agonal l y spl i tti ng the
brakes hydraul i c system.
Vehi cl es not equi pped wi th ABS brakes use a
hei ght sensi ng proporti oni ng val ve. The hei ght sens-
i ng proporti oni ng val ve i s mounted on the l eft frame
rai l at the rear of the vehi cl e (Fi g. 8). The hei ght
sensi ng proporti oni ng val ve uses an actuator assem-
bl y (Fi g. 8) to attach the proporti oni ng val ve to the
l eft rear spri ng for sensi ng changes i n vehi cl e hei ght.
HEIGHT SENSING PROPORTIONING VALVE OPERATION
The hei ght sensi ng proporti oni ng val ve regul ates
the hydraul i c pressure to the rear brakes. The pro-
porti oni ng val ve regul ates the pressure by sensi ng
the l oad condi ti on of the vehi cl e through the move-
ment of the proporti oni ng val ve actuator assembl y
Fig. 6 Fixed Proportioning Valve Location
Fig. 7 Junction Block Location
Fig. 8 Height Sensing Proportioning Valve
5 - 6 BRAKES NS
(Fi g. 8). The actuator assembl y i s mounted between
the hei ght sensi ng proporti oni ng val ve and the actua-
tor bracket on the l eft rear l eaf spri ng (Fi g. 8). As the
rear hei ght of the vehi cl e changes dependi ng on the
l oad the vehi cl e i s carryi ng the hei ght change i s
transferred to the hei ght sensi ng proporti oni ng val ve.
Thi s change i n vehi cl e hei ght i s transferred through
the movement of the l eft rear l eaf spri ng. As the posi -
ti on of the l eft rear l eaf spri ng changes thi s move-
ment i s transferred through the actuator bracket
(Fi g. 8) to the actuator assembl y (Fi g. 8) and then to
the proporti oni ng val ve.
Thus, the hei ght sensi ng proporti oni ng val ve
al l ows the brake system to mai ntai n the opti mal
front to rear brake bal ance regardl ess of the vehi cl e
l oad condi ti on. Under a l i ght l oad condi ti on, hydrau-
l i c pressure to the rear brakes i s mi ni mi zed. As the
l oad condi ti on of the vehi cl e i ncreases, so does the
hydraul i c pressure to the rear brakes.
The proporti oni ng val ve secti on of the val ve oper-
ates by transmi tti ng ful l i nput hydraul i c pressure to
the rear brakes up to a certai n poi nt, cal l ed the spl i t
poi nt. Beyond the spl i t poi nt the proporti oni ng val ve
reduces the amount of hydraul i c pressure to the rear
brakes accordi ng to a certai n rati o. Thus, on l i ght
brake appl i cati ons, approxi matel y equal hydraul i c
pressure wi l l be transmi tted to the front and rear
brakes. At heavi er brake appl i cati ons, the hydraul i c
pressure transmi tted to the rear brakes wi l l be l ower
then the front brakes. Thi s wi l l prevent premature
rear wheel l ock-up and ski d.
The hei ght sensi ng secti on of the val ve thus
changes the spl i t poi nt of the proporti oni ng val ve,
based on the rear suspensi on hei ght of the vehi cl e.
When the hei ght of the rear suspensi on i s l ow, the
proporti oni ng val ve i nterprets thi s as extra l oad and
the spl i t poi nt of the proporti oni ng val ve i s rai sed to
al l ow more rear braki ng. When the hei ght of the rear
suspensi on i s hi gh, the proporti oni ng val ve i nterprets
thi s as a l i ghtl y l oaded vehi cl e and the spl i t poi nt of
the proporti oni ng val ve i s l owered and rear braki ng
i s reduced.
CHASSIS TUBES AND HOSES
The purpose of the chassi s brake tubes and fl ex
hoses i s to transfer the pressuri zed brake fl ui d devel -
oped by the master cyl i nder to the wheel brakes of
the vehi cl e. The chassi s tubes are steel wi th a corro-
si on resi stant coati ng appl i ed to the external surfaces
and the fl ex hoses are made of rei nforced rubber. The
rubber fl ex hoses al l ow for the movement of the vehi -
cl es suspensi on.
MASTER CYLINDER
The master cyl i nder (Fi g. 9) consi sts of the fol l ow-
i ng components. The body of the master cyl i nder i s
an anodi zed al umi num casti ng. I t has a machi ned
bore to accept the master cyl i nder pi ston and
threaded ports wi th seats for the hydraul i c brake
l i ne connecti ons. The brake fl ui d reservoi r of the
master cyl i nder assembl y i s made of a see through
pol ypropyl ene type pl asti c. A l ow fl ui d swi tch i s al so
part of the reservoi r assembl y.
Thi s vehi cl e uses 3 di fferent master cyl i nders.
Master cyl i nder usage depends on what type of brake
system the vehi cl e i s equi pped wi th. I f a vehi cl e i s
not equi pped wi th anti l ock brakes, or i s equi pped
wi th anti l ock brakes wi thout tracti on control , a con-
venti onal compensati ng port master cyl i nder i s used.
I f a vehi cl e i s equi pped wi th anti l ock brakes wi th
tracti on control , a dual center port master cyl i nder i s
used.
The thi rd master cyl i nder used on thi s vehi cl e i s
uni que to vehi cl es equi pped wi th four wheel di sc
brakes. The master cyl i nder used for thi s brake
appl i cati on has a di fferent bore di ameter and stroke
then the master cyl i nder used for the other avai l abl e
brake appl i cati ons.
The master cyl i nders used on front wheel dri ve
appl i cati ons (non four wheel di sc brake vehi cl es)
have a master cyl i nder pi ston bore di ameter of 23.8
mm. The master cyl i nder used on the al l wheel dri ve
appl i cati ons (four wheel di sc brake vehi cl es) have a
master cyl i nder pi ston bore di ameter of 25.4 mm.
When replacing a master cylinder, be sure to
use the correct master cylinder for the type of
brake system the vehicle is equipped with.
The master cyl i nder i s not a repai rabl e component
and must be repl aced i f di agnosed to be functi oni ng
i mproperl y
CAUTION: Do not hone the bore of the cylinder as
this will remove the anodized surface from the bore.
The master cyl i nder pri mary outl et port suppl i es
hydraul i c pressure to the ri ght front and l eft rear
Fig. 9 Master Cylinder Assembly
NS BRAKES 5 - 7
brakes. The secondary outl et port suppl i es hydraul i c
pressure to the l eft front and ri ght rear brakes.
POWER BRAKE VACUUM BOOSTER OPERATION
Al l vehi cl es use a 270 mm si ngl e di aphragm power
brake vacuum booster.
The power brake booster can be i denti fi ed i f
requi red, by the tag attached to the body of the
booster assembl y (Fi g. 10). Thi s tag contai ns the fol -
l owi ng i nformati on: The producti on part number of
the power booster assembl y, the date i t was bui l t,
and who was the manufacturer of the power brake
vacuum booster.
NOTE: The power brake booster assembly is not a
repairable component and must be replaced as a
complete assembly if it is found to be faulty in any
way. The check valve located in the power brake
booster (Fig. 10) is not repairable but it can be
replaced as an assembly separate from the power
brake booster.
The power brake booster reduces the amount of
force requi red by the dri ver to obtai n the necessary
hydraul i c pressure to stop vehi cl e.
The power brake booster i s vacuum operated. The
vacuum i s suppl i ed from the i ntake mani fol d on the
engi ne through the power brake booster check val ve
(Fi g. 10) and (Fi g. 11).
As the brake pedal i s depressed, the power brake
boosters i nput rod moves forward (Fi g. 11). Thi s
opens and cl oses val ves i n the power booster, al l ow-
i ng atmospheri c pressure to enter on one si de of a
di aphragm. Engi ne vacuum i s al ways present on the
other si de. Thi s di fference i n pressure forces the out-
put rod of the power booster (Fi g. 11) out agai nst the
pri mary pi ston of the master cyl i nder. As the pi stons
i n the master cyl i nder move forward thi s creates the
hydraul i c pressure i n the brake system.
The di fferent engi ne combi nati ons used on thi s
vehi cl e requi re that di fferent vacuum hose routi ngs
to the power brake vacuum booster be used.
Al l vacuum hoses must be routed from the engi ne
to the power brake vacuum booster wi thout ki nks,
excessi vel y ti ght bends or potenti al for damage to the
vacuum hose.
The power brake vacuum booster assembl y mounts
on the engi ne si de of the dash panel , and i s con-
nected to the brake pedal by the i nput push rod (Fi g.
11). A vacuum l i ne connects the power booster to the
i ntake mani fol d. The master cyl i nder i s bol ted to the
front of the power brake vacuum booster assembl y.
RED BRAKE WARNING LAMP OPERATION
The red Brake warni ng l amp i s l ocated i n the
i nstrument panel cl uster and i s used to i ndi cate a
l ow brake fl ui d condi ti on or that the parki ng brake i s
appl i ed. I n addi ti on, the brake warni ng l amp i s
turned on as a bul b check by the i gni ti on swi tch
every ti me the i gni ti on swi tch i s turned to the crank
posi ti on.
The warni ng l amp bul b i s suppl i ed a 12 vol t i gni -
ti on feed anyti me the i gni ti on swi tch i s on. The bul b
i s then i l l umi nated by compl eti ng the ground ci rcui t
ei ther through the park brake swi tch, the fl ui d l evel
sensor i n the master cyl i nder reservoi r, or the i gni -
ti on swi tch when i t i s turned to the crank posi ti on.
The Brake Fl ui d Level sensor i s l ocated i n the
brake fl ui d reservoi r of the master cyl i nder assembl y.
The purpose of the sensor i s to provi de the dri ver
wi th an earl y warni ng that brake fl ui d l evel i n the
master cyl i nder fl ui d reservoi r has dropped to bel ow
Fig. 10 Power Brake Booster Identification
Fig. 11 Power Brake Booster Assembly
5 - 8 BRAKES NS
normal . Thi s may i ndi cate: (1) Abnormal l oss of
brake fl ui d i n the master cyl i nder fl ui d reservoi r
resul ti ng from a l eak i n the hydraul i c system. (2)
Brake shoe linings which have worn to a point
requiring replacement.
As the brake fl ui d drops bel ow the mi ni mum l evel ,
the brake fl ui d l evel sensor cl oses to ground the
brake warni ng l i ght ci rcui t. Thi s wi l l turn on the red
brake warni ng l i ght. At thi s ti me, master cyl i nder
fl ui d reservoi r shoul d be checked and fi l l ed to the ful l
mark wi th DOT 3 brake fl ui d. If brake fluid level
has dropped below the add line in the master
cylinder fluid reservoir, the entire brake
hydraulic system should be checked for evi-
dence of a leak.
STOP LAMP SWITCH
The stop l amp swi tch control s operati on of the
vehi cl es stop l amps. Al so, i f the vehi cl e i s equi pped
wi th speed control , the stop l amp swi tch wi l l deacti -
vate speed control when the brake pedal i s
depressed.
The stop l amp swi tch control s operati on of the
ri ght and l eft tai l , stop and turn si gnal l amp and
CHMSL l amp, by suppl yi ng battery current to these
l amps.
The stop l amp swi tch control s the l amp operati on
by openi ng and cl osi ng the el ectri cal ci rcui t to the
stop l amps.
HUB/BEARING REAR WHEEL
The rear hub and beari ng assembl y used on thi s
vehi cl e i s servi ceabl e onl y as a compl ete assembl y. No
attempt shoul d be made to di sassembl e a rear hub
and beari ng assembl y i n an effort to repai r i t.
The rear hub and beari ng assembl y i s attached to
the rear axl e usi ng 4 mounti ng bol ts that are remov-
abl e from the back of the rear hub/beari ng.
BRAKE SYSTEM BASIC DIAGNOSIS GUIDE
SYMPTOM
CHART 1
MISC.
COND.
CHART 2
WARNING
LIGHT
CHART 3
POWER
BRAKES
CHART 4
BRAKE
NOISE
CHART 5
WHEEL
BRAKES
Brake Warning Light On X NO NO
Excessive Pedal Travel 6 X NO O
Pedal Goes To The Floor 6 X
Stop Light On Without Brakes 3
All Brakes Drag 5
Rear Brakes Drag 2 NO NO
Grabby Brakes O X
Spongy Brake Pedal X NO
Premature Rear Brake Lockup 4 NO NO O
Excessive Pedal Effort 1 O
Rough Engine Idle NO O
Brake Chatter (Rough) NO NO X
Surge During Braking NO NO X
Noise During Braking NO NO X
Rattle Or Clunking Noise NO NO X
Pedal Pulsates During Braking NO NO X
Pull To Right Or Left NO NO X
No: Not A Possible Cause X: Most Likely Cause O: Possible Cause
NS BRAKES 5 - 9
BRAKE SYSTEM DIAGNOSIS CHARTS
MISCELLANEOUS BRAKE SYSTEM CONDITIONS
5 - 10 BRAKES NS
RED BRAKE WARNING LAMP FUNCTION
NS BRAKES 5 - 11
POWER BRAKE SYSTEM DIAGNOSTICS
5 - 12 BRAKES NS
VEHICLE ROAD TEST
BRAKE NOISE
NS BRAKES 5 - 13
ADJUSTER REAR DRUM BRAKE (AUTOMATIC)
The rear drum brakes on thi s vehi cl e automati cal l y
adjust, when requi red, duri ng the normal operati on
of the vehi cl e every ti me the brakes are appl i ed. Use
the fol l owi ng procedure to test the operati on of the
automati c adjuster.
Pl ace the vehi cl e on a hoi st wi th a hel per i n the
dri vers seat to appl y the brakes. Remove the access
pl ug from the adjustment hol e i n each brake support
pl ate to provi de vi sual access of the brake adjuster
star wheel .
Remove the park brake cabl e, for the wheel of the
vehi cl e that i s bei ng worked on, from the park brake
cabl e equal i zer (Fi g. 12). Thi s i s requi red to gai n
access to the star wheel . I f the cabl e i s not removed
from the equal i zer, the cabl e and spri ng i nsi de of the
brake drum i s i n the way of the star wheel .
To el i mi nate the condi ti on where maxi mum adjust-
ment of the rear brake shoes, does not al l ow the
automati c adjuster to operate when tested, back the
star wheel off approxi matel y 30 notches. I t wi l l be
necessary to hol d the adjuster l ever away from the
star wheel to permi t thi s adjustment.
Have the hel per appl y the brakes. Upon appl i ca-
ti on of the brake pedal , the adjuster l ever l ever
shoul d move down, turni ng the adjuster star wheel .
Thus, a defi ni te rotati on of the adjuster star wheel
can be observed i f the automati c adjuster i s worki ng
properl y. I f one or more adjusters do not functi on
properl y, the respecti ve drum must be removed for
adjuster servi ci ng.
BRAKE ROTOR
Any servi ci ng of the rotor requi res extreme care to
mai ntai n the rotor to wi thi n servi ce tol erances to
ensure proper brake acti on.
Before refi ni shi ng or refaci ng a rotor, the rotor
shoul d be checked and i nspected for the fol l owi ng
condi ti ons:
Braki ng surface scori ng, rust, i mpregnati on of l i n-
i ng materi al and worn ri dges.
Excessi ve rotor l ateral runout or wobbl e.
Thi ckness vari ati on i n braki ng surface of the rotor
(Paral l el i sm).
Di shi ng or di storti on i n braki ng surface of the
rotor (Fl atness).
I f a vehi cl e has not been dri ven for a peri od of
ti me, the rotors wi l l rust i n the area not covered by
the brake l i ni ng and cause noi se and chatter when
the brakes are appl i ed.
Excessi ve wear and scori ng of the rotor can cause
temporary i mproper l i ni ng contact i f ri dges are not
removed from braki ng surface of rotor before i nstal -
l ati on of new brake shoe assembl i es.
Some di scol orati on and/or wear of the rotor surface
i s normal and does not requi re resurfaci ng when l i n-
i ngs are repl aced.
Excessi ve runout or wobbl e i n a rotor can i ncrease
pedal travel due to pi ston knock-back. Thi s wi l l al so
i ncrease gui de pi n bushi ng wear due to the tendency
of the cal i per to fol l ow rotor wobbl e.
Thi ckness vari ati on i n a rotor can al so resul t i n
pedal pul sati on, chatter and surge due to vari ati on i n
brake output. Thi s can al so be caused by excessi ve
runout i n the rotor and/or the hub.
Di shi ng or di storti on can be caused by extreme
heat and abuse of the brakes.
CHECKING ROTOR FOR RUNOUT AND
THICKNESS
NOTE: The procedure for checking rotor runout
and thickness is the same for the front and rear
rotor. If there is a specification difference between
the front and rear rotor it will be designated as
such in the specifications of the following proce-
dure.
On-vehi cl e rotor runout i s the combi nati on of the
i ndi vi dual runout of the hub face and the runout of
the rotor. (The hub and rotor runouts are separabl e).
To measure runout on the vehi cl e, remove the wheel
and rei nstal l the l ug nuts ti ghteni ng the rotor to the
hub. Mount Di al I ndi cator, Speci al Tool C-3339 wi th
Mounti ng Adaptor, Speci al Tool SP- 1910 on steeri ng
arm. Di al i ndi cator pl unger shoul d contact braki ng
surface of rotor approxi matel y 10 mm (0.393 i n.)
from outer edge of rotor (Fi g. 13). Check l ateral
runout on both si des of rotor. Lateral runout of the
rotor shoul d not exceed 0.13 mm (0.005 i nch).
I f l ateral runout i s i n excess of the speci fi cati on,
check the l ateral runout of the hub face. Before
removi ng rotor from hub, make a chal k mark across
Fig. 12 Park Brake Cable Equlizer
5 - 14 BRAKES NS
both the rotor and one wheel stud on the hi gh si de of
the runout. Thi s wi l l ensure that the ori gi nal l ocati on
of the rotor i n rel ati on to the hub can be retai ned
(Fi g. 14). Remove rotor from hub.
Thoroughl y cl ean the front surface of the front
hub. Then i nstal l Di al I ndi cator, Speci al Tool C-3339
and Mounti ng Adaptor, Speci al Tool SP-1910 on
steeri ng knuckl e. Posi ti on stem so i t contacts hub
face near outer di ameter. Care must be taken to posi -
ti on stem outsi de the stud ci rcl e but i nsi de the cham-
fer on the hub face (Fi g. 15). Clean hub surface
before checking.
Lateral runout shoul d not exceed 0.08 mm (0.003
i nch). I f runout exceeds thi s speci fi cati on, the hub
must be repl aced. See Suspensi on Group 2. I f l ateral
runout of the hub does not exceed thi s speci fi cati on,
i nstal l rotor on hub wi th chal k marks two wheel
studs apart (Fi g. 16). Ti ghten nuts i n the properse-
quence and torque to speci fi cati on. Fi nal l y, check l at-
eral runout of rotor to see i f l ateral runout i s now
wi thi n speci fi cati on.
I f l ateral runout i s not wi thi n speci fi cati on, i nstal l
a new rotor or reface rotor, bei ng careful to remove
as l i ttl e rotor materi al as possi bl e from each si de of
rotor. Remove equal amounts from each si de of rotor.
Do not reduce thi ckness bel ow mi ni mum thi ckness
marki ng cast i nto the un-machi ned surface (Fi g. 17)
of the rotor .
Thi ckness vari ati on measurements of the rotor
shoul d be made i n conjuncti on wi th the l ateral
runout measurements. Measure the thi ckness of the
rotor at 12 ci rcumferenti al l y equal poi nts wi th a
Fig. 16 Indexing Rotor And Wheel Stud
Fig. 13 Checking Brake Rotor For Runout
Fig. 14 Marking Rotor And Wheel Stud
Fig. 15 Checking Disc Brake Rotor For Runout
NS BRAKES 5 - 15
mi crometer at a radi us approxi matel y 25.4 mm (1
i nch) from outer edge of rotor (Fi g. 18). I f thi ckness
measurements vary by more than 0.013 mm (0.0005
i nch), rotor shoul d be removed and resurfaced, or a
new rotor i nstal l ed. I f cracks or burned spots are evi -
dent, rotor must be repl aced.
Li ght scori ng and/or wear i s acceptabl e. I f heavy
scori ng or warpi ng i s evi dent, the rotor must be
refi ni shed or repl aced (See Refi ni shi ng/Refaci ng
Rotor). I f cracks are evi dent i n the rotor, repl ace the
rotor.
FIXED PROPORTIONING VALVE TEST
PROCEDURE
On a vehi cl e equi pped wi th ABS, premature or
excessi ve rear wheel ABS cycl i ng may be an i ndi ca-
ti on that the brake fl ui d pressure to the rear brakes
i s above the desi red output.
Pri or to testi ng a proporti oni ng val ve for functi on,
check that al l ti re pressures are correct. Al so, ensure
the front and rear brake l i ni ngs are i n sati sfactory
condi ti on. It is also necessary to verify that the
brakes shoe assemblies on a vehicle being
tested, are either original equipment manufac-
turers (OEM), or original replacement brake
shoe assemblies meeting the OEM lining mate-
rial specification. The vehicles brake system is
not balanced for after market brake shoe
assembly lining material.
I f brake shoe assembl y l i ni ng materi al i s of sati s-
factory condi ti on, and of the correct materi al speci fi -
cati on, check for proper proporti oni ng val ve functi on
usi ng the fol l owi ng procedure.
(1) Road test vehi cl e to be sure the vehi cl e i s trul y
exhi bi ti ng a condi ti on of excessi ve rear wheel ABS
cycl i ng. Si nce ABS cycl es both rear brakes together
both proportioning valves of the assembly (Fi g.
19) must be tested. Use the fol l owi ng procedure to
test the proporti oni ng val ve.
(2) Remove one of the chassi s brake l i nes (Fi g. 19)
comi ng from the ABS modul ator, at
(3) the proporti oni ng val ve assembl y. Remove the
hydraul i c brake l i ne goi ng to one of the rear wheel s
of the vehi cl e from the proporti oni ng val ve (Fi g. 19)
Fig. 17 Minimum Rotor Thickness Markings
Fig. 18 Checking Rotor For Thickness Variation
Fig. 19 Rear Brake Proportioning Valve And Brake
Tube Locations
5 - 16 BRAKES NS
(4) Remove the 2 bol ts (Fi g. 19) attachi ng the pro-
porti oni ng val ve to the frame rai l .
CAUTION: When lowering the proportioning valve,
care must be taken not to kink any of the chassis
brake lines.
(5) Careful l y l ower the proporti oni ng val ve for
cl earance to i nstal l the proporti oni ng val ve test fi t-
ti ngs.
(6) I nstal l the requi red fi tti ng from Pressure Test
Fi tti ngs, Speci al Tool 6833 (Fi g. 20) i nto the i nl et
port of the proporti oni ng val ve assembl y, from whi ch
the chassi s brake l i ne was removed. I nstal l the
removed chassi s brake l i ne i nto the Pressure Test
Fi tti ng (Fi g. 20). I nstal l the requi red fi tti ng from
Pressure Test Fi tti ngs, Speci al Tool 6833 i nto the
requi red outl et port of the proporti oni ng val ve.
I nstal l the requi red fi tti ng from Pressure Test Fi t-
ti ngs, Speci al Tool 6833 i nto the requi red outl et port
of the proporti oni ng val ve (Fi g. 20). Then i nstal l the
Fi tti ng (Fi g. 20).
(7) I nstal l a pressure gauge from Gauge Set, Spe-
ci al Tool C-4007-A i nto each pressure test fi tti ng (Fi g.
21). Bl eed ai r out of hose from pressure test fi tti ngs
to pressure gauges, at the pressure gauges (Fi g. 21).
Then bl eed ai r out of the brake l i ne bei ng tested, at
that rear wheel cyl i nder.
(8) Wi th the ai d of a hel per, appl y pressure to the
brake pedal unti l a pressure of 6895 kPa (1000 psi ) i s
obtai ned on the proporti oni ng val ve i nl et gauge.
Then based on the type of brake system the vehi cl e i s
equi pped wi th and the pressure speci fi cati on shown
on the fol l owi ng tabl e, compare the pressure readi ng
on the outl et gauge to the speci fi cati on. I f outl et
pressure at the proporti oni ng val ve i s not wi thi n
speci fi cati on when requi red i nl et pressure i s
obtai ned, repl ace the proporti oni ng val ve.
(9) Repeat steps 2 through 7 for the other propor-
ti oni ng val ve of the assembl y.
CAUTION: When mounting the original or a
replacement proportion valve on the frame rail of
the vehicle install the mounting bolts in only the
two forward holes of the mounting bracket (Fig. 19).
HEIGHT SENSING PROPORTIONING VALVE
CAUTION: The use of after-market load leveling or
load capacity increasing devices on this vehicle are
prohibited. Using air shock absorbers or helper
springs on this vehicle will cause the height sens-
ing proportioning valve to inappropriately reduce
the hydraulic pressure to the rear brakes. This inap-
propriate reduction in hydraulic pressure potentially
could result in increased stopping distance of the
vehicle.
When a premature rear wheel ski d i s obtai ned on a
brake appl i cati on, i t may be an i ndi cati on that the
hydraul i c pressure to the rear brakes i s above the
speci fi ed output from the proporti oni ng val ve. Thi s
condi ti on i ndi cates a possi bl e mal functi on of the
hei ght sensi ng proporti oni ng val ve, whi ch wi l l
requi re testi ng to veri fy that i t i s properl y control l i ng
the hydraul i c pressure al l owed to the rear brakes.
Premature rear wheel ski d may al so be caused by an
i ncorrectl y adjusted proporti oni ng val ve actuator
assembl y, or contami nated front or rear brake l i n-
i ngs.
Pri or to testi ng a proporti oni ng val ve for functi on,
check that al l ti re pressures are correct. Al so, ensure
the front and rear brake l i ni ngs are i n sati sfactory
condi ti on. It is also necessary to verify that the
brakes shoe assemblies on a vehicle being
tested, are either original equipment manufac-
turers (OEM), or original replacement brake
Fig. 20 Proportioning Valve Test Fitting Installation
Fig. 21 Pressure Gauges Installed On Pressure Test
Fittings
NS BRAKES 5 - 17
shoe assemblies meeting the OEM lining mate-
rial specification. The vehicles brake system is
not balanced for after market brake shoe
assembly lining material.
I f both front and rear brakes check OK, proceed to
veri fy that the actuator assembl y for the hei ght sens-
i ng proporti oni ng val ve i s adjusted correctl y. See
Hei ght Sensi ng Proporti oni ng Val ve i n the Adjust-
ment Secti on i n thi s group of the servi ce manual for
the adjustment procedure. I f the proporti oni ng val ve
i s adjusted correctl y, proceed wi th the test procedure
for the hei ght sensi ng proporti oni ng val ve as fol l ows:
(1) Remove the actuator assembl y adjustment nut
(Fi g. 22). Remove the actuator assembl y from the
l ever on the hei ght sensi ng proporti oni ng val ve.
(2) Remove the chassi s brake tube comi ng from
the juncti on bl ock from the front of the hei ght sens-
i ng proporti oni ng val ve (Fi g. 23). Remove the chassi s
brake tube goi ng to the rear brakes from the back of
the hei ght sensi ng proporti oni ng val ve (Fi g. 23).
(3) I nstal l the requi red fi tti ngs from Pressure Test
Fi tti ngs, Speci al Tool 6833 (Fi g. 24) i nto the i nl et
port of the proporti oni ng val ve assembl y, from whi ch
the chassi s brake l i ne was removed. I nstal l the
Fi tti ng (Fi g. 24). I nstal l the requi red fi tti ng from
Pressure Test Fi tti ngs, Speci al Tool 6833 i nto the
requi red outl et port of the proporti oni ng val ve.
I nstal l the requi red fi tti ng from Pressure Test Fi t-
ti ngs, Speci al Tool 6833 i nto the requi red outl et port
of the proporti oni ng val ve (Fi g. 24). Then i nstal l the
Fi tti ng (Fi g. 20).
(4) I nstal l a pressure gauge from Gauge Set, Spe-
ci al Tool C-4007-A i nto each pressure test fi tti ng (Fi g.
25). Bl eed ai r out of hose from pressure test fi tti ngs
to pressure gauges, at the pressure gauges (Fi g. 25).
Then bl eed ai r out of the brake l i ne bei ng tested, at
that rear wheel cyl i nder.
Fig. 22 Actuator Assembly Adjustment Nut
Fig. 23 Brake Tube Connections To Proportioning
Valve
Fig. 24 Proportioning Valve Test Fitting Installation
Fig. 25 Pressure Gauges Installed On Pressure Test
Fittings
5 - 18 BRAKES NS
(5) Wi th the ai d of a hel per, appl y pressure to the
brake pedal unti l a pressure of 6895 kPa (1000 psi ) i s
obtai ned on the proporti oni ng val ve i nl et gauge.
Then based on the type of brake system the vehi cl e i s
equi pped wi th and the pressure speci fi cati on shown
on the fol l owi ng tabl e, compare the pressure readi ng
on the outl et gauge to the speci fi cati on. I f outl et
pressure at the proporti oni ng val ve i s not wi thi n
speci fi cati on when requi red i nl et pressure i s
obtai ned, repl ace the proporti oni ng val ve.
(6) Remove the pressure test fi tti ngs and pressure
gauges from the proporti oni ng val ve.
(7) I nstal l the chassi s brake l i nes i n the correct
ports of the proporti oni ng val ve.
(8) I nstal l the pressure test fi tti ngs and pressure
gauges i n the opposi te i nl et and outl et port of the
hei ght sensi ng proporti oni ng val ve. Repeat steps 4
and 5 for the other proporti oni ng val ve.
(9) Remove the pressure test fi tti ngs and pressure
gauges from the proporti oni ng val ve.
(10) I nstal l the chassi s brake l i nes i n the correct
ports of the proporti oni ng val ve.
(11) I nstal l the actuator (Fi g. 22) on the hei ght
sensi ng proporti oni ng val ve. Adjust the proporti oni ng
val ve actuator. See Hei ght Sensi ng Proporti oni ng
Val ve i n the Adjustment Secti on i n thi s group of the
servi ce manual for the adjustment procedure.
(12) Bl eed both rear hydraul i c ci rcui ts at the rear
brakes.
(13) Road test vehi cl e.
BRAKE FLUID CONTAMINATION
I ndi cati ons of fl ui d contami nati on are swol l en or deteri -
orated rubber parts.
Swol l en rubber parts i ndi cate the presence of
petrol eum i n the brake fl ui d.
To test for contami nati on, put a smal l amount of
drai ned brake fl ui d i n cl ear gl ass jar. I f fl ui d sepa-
rates i nto l ayers, there i s mi neral oi l or other fl ui d
contami nati on of the brake fl ui d.
I f brake fl ui d i s contami nated, drai n and thor-
oughl y fl ush system. Repl ace master cyl i nder, propor-
ti oni ng val ve, cal i per seal s, wheel cyl i nder seal s,
Anti l ock Brakes hydraul i c uni t and al l hydraul i c
fl ui d hoses.
RED BRAKE WARNING LAMP TEST
For di agnosi s of speci fi c probl ems wi th the red
brake warni ng l amp system, refer to Brake System
Di agnosti cs Chart 2, l ocated i n the Di agnosi s And
Testi ng secti on i n thi s group of the servi ce manual .
TRACTION CONTROL LAMP TEST
The tracti on control l i ght i s tested by cycl i ng the
tracti on control swi tch on and off. The tracti on con-
trol swi tch used on thi s vehi cl e i s a momentary con-
tact type swi tch. The test procedure for the tracti on
control l i ght i s performed as fol l ows: Press the trac-
ti on control swi tch once and the Trac Off l amp wi l l
i l l umi nate. Wi th the Trac Off l amp i l l umi nated,
press the tracti on control swi tch agai n and the Trac
Off l amp wi l l turn off.
I f the tracti on control l amp does not functi on as
descri bed i n the test above, di agnosi s of the tracti on
control swi tch, l amp, wi ri ng and other rel ated compo-
nents of the tracti on control system i s requi red.
STOP LAMP SWITCH TEST PROCEDURE
The requi red procedure for testi ng the stop l amp
swi tch i s covered i n Group 8H, Vehi cl e Speed Control
System i n thi s servi ce manual . The el ectri cal ci rcui t
tests for stop l amps i s covered i n Group 8W Rear-
Li ghti ng i n thi s servi ce manual .
WHEEL
BASE
DRIVE
TRAIN
SALES CODE
BRAKE SYS-
TEM
SPLIT POINT SLOPE
INLET PRES-
SURE PSI
OUTLET
PRESSURE
PSI
SWB FWD BRA+BGF
14 DISC/DRUM
W/O ANTILOCK
VAR. .30 1000 PSI 250-350 PSI
SWB FWD
BRA+BGF
BRB+BGF
BRV+BGF
14,15,15HD
DISC/DRUM
WITHANTILOCK
25 BAR .59 1000 PSI
660-780
PSI
LWB FWD BRA+BGF
14 DISC/DRUM
W/O ANTILOCK
VAR. .30 1000 PSI 250-350 PSI
LWB FWD
BRA+BGF
BRB+BGF
BRV+BGF
14,15,15HD
DISC/DRUM
WITHANTILOCK
25 BAR .59 1000 PSI 660-780 PSI
SWB AWD BRE+BGF
15 DISC/DISC
WITHANTILOCK
25 BAR .36 1000 PSI 525-640 PSI
LWB AWD BRE+BGF
15 DISC/DISC
WITHANTILOCK
41 BAR .36 1000 PSI 690-800 PSI
NS BRAKES 5 - 19
SERVICE PROCEDURES
MASTER CYLINDER FLUID LEVEL CHECK
Check master cyl i nder reservoi r fl ui d l evel a mi ni -
mum of twi ce annual l y.
Master cyl i nder reservoi rs are marked wi th the
words FULL and ADD to i ndi cate proper brake fl ui d
fi l l l evel of the master cyl i nder (Fi g. 26).
I f necessary, add brake fl ui d to bri ng the l evel to
the bottom of the FULL mark on the si de of the mas-
ter cyl i nder fl ui d reservoi r. When filling master
cylinder fluid reservoir do not fill the filler
neck of the fluid reservoir (Fig. 26) with brake
fluid.
Use onl y Mopar brake fl ui d or an equi val ent from
a seal ed contai ner. Brake fl ui d must conform to DOT
3, speci fi cati ons.
DO NOT use brake fl ui d wi th a l ower boi l i ng
poi nt, as brake fai l ure coul d resul t duri ng prol onged
hard braki ng.
Use onl y brake fl ui d that was stored i n a ti ghtl y-
seal ed contai ner.
DO NOT use petrol eum-based fl ui d because seal
damage wi l l resul t. Petrol eum based fl ui ds woul d be
i tems such as engi ne oi l , transmi ssi on fl ui d, power
steeri ng fl ui d ect.
BLEEDING BASE BRAKE HYDRAULIC SYSTEM
NOTE: This bleeding procedure is only for the vehi-
cles base brakes hydraulic system. For bleeding
the antilock brakes hydraulic system, refer to the
ITT Teves Mark 20 Antilock Brake System bleeding
procedure in the antilock brakes section of this ser-
vice manual.
PRESSURE BLEEDING PROCEDURE
CAUTION: Before removing the master cylinder
cover, throughly clean the cover and master cylin-
der fluid reservoir to prevent dirt and other foreign
matter from dropping into the master cylinder fluid
reservoir.
CAUTION: Use bleeder tank Special Tool C-3496-B
with adapter Special Tool 6921 to pressurize the
hydraulic system for bleeding.
CAUTION: When pressure bleeding the brakes
hydraulic system the fluid reservoir filler neck must
be removed from the master cylinder fluid reservoir.
Failure to remove the filler neck from the fluid res-
ervoir, may result in the filler neck separating from
the fluid reservoir when the hydraulic system is
pressurized.
Fol l ow pressure bl eeder manufacturers i nstruc-
ti ons, for use of pressure bl eedi ng equi pment.
When bl eedi ng the brake system, some ai r may be
trapped i n the brake l i nes or val ves far upstream, as
much as ten feet from the bl eeder screw (Fi g. 27).
Therefore, i t i s essenti al to have a fast fl ow of a l arge
vol ume of brake fl ui d when bl eedi ng the brakes to
ensure al l the ai r gets out.
(1) Remove the fi l l er neck from the master cyl i n-
der fl ui d reservoi r.
(2) I nstal l the Adapter Master Cyl i nder Pressure
Bl eed Cap, Speci al Tool 6921 on the fl ui d reservoi r of
the master cyl i nder (Fi g. 28). Attach the fl ui d hose
from the pressure bl eeder to the fi tti ng on Speci al
Tool 6921.
(3) Attach a cl ear pl asti c hose to the bl eeder screw
at one wheel and feed the hose i nto a cl ear jar con-
tai ni ng fresh brake fl ui d.
Fig. 26 Master Cylinder Fluid Level Marks
Fig. 27 Trapped Air In Brake Fluid Line
5 - 20 BRAKES NS
NOTE: The following wheel sequence should be
used when bleeding the brake hydraulic system.
The use of this wheel sequence will ensure ade-
quate removal of all trapped air from the brake
hydraulic system.
Left Rear Wheel
Ri ght Front Wheel
Ri ght Rear Wheel
Left Front Wheel
(4) Open the l eft rear wheel bl eeder screw at l east
one full turn or more to obtai n an adequate fl ow of
brake fl ui d (Fi g. 29).
CAUTION: Just cracking the bleeder screw often
restricts fluid flow, and a slow, weak fluid discharge
will NOT get all the air out.
(5) After 4 to 8 ounces of brake fl ui d has been bl ed
through the hydraul i c system, and an ai r-free fl ow i s
mai ntai ned i n the hose and jar, thi s wi l l i ndi cate a
good bl eed of the hydraul i c system has been
obtai ned.
(6) Repeat the procedure at al l the other remai n-
i ng bl eeder screws. Then check the pedal for travel .
I f pedal travel i s excessi ve or has not been i mproved,
enough fl ui d has not passed through the system to
expel al l the trapped ai r. Be sure to moni tor the fl ui d
l evel i n the pressure bl eeder, so i t stays at a proper
l evel so ai r wi l l not enter the brake system through
the master cyl i nder.
(7) Perform a fi nal adjustment of the rear brake
shoes and then test dri ve vehi cl e to be sure brakes
are operati ng correctl y and that pedal i s sol i d.
BLEEDING WITHOUT A PRESSURE BLEEDER
NOTE: Correct manual bleeding of the brakes
hydraulic system will require the aid of a helper.
NOTE: To adequately bleed the brakes using the
manual bleeding procedure the rear brakes must be
correctly adjusted. Prior to the manual bleeding of
the brake hydraulic system, correctly adjust the
rear brakes.
NOTE: The following wheel sequence should be
used when bleeding the brake hydraulic system.
The use of this wheel sequence will ensure ade-
quate removal of all trapped air from the brake
hydraulic system.
Left Rear Wheel
Ri ght Front Wheel
Ri ght Rear Wheel
Left Front Wheel
(1) Pump the brake pedal three or four ti mes and
hol d i t down before the bl eeder screw i s opened.
(2) Push the brake pedal toward the fl oor and hol d
i t down. Then open the l eft rear bl eeder screw at
l east 1 ful l turn. When the bl eeder screw opens the
brake pedal wi l l drop al l the way to the fl oor.
(3) Rel ease the brake pedal onl y after the bl eeder
screw i s cl osed.
(4) Repeat steps 1 through 3, four or fi ve ti mes, at
each bl eeder screw i n the requi red sequence. Thi s
shoul d pass a suffi ci ent amount of fl ui d to expel al l
the trapped ai r from the brake system. Be sure to
moni tor the fl ui d l evel i n the master cyl i nder, so i t
stays at a proper l evel so ai r wi l l not enter the brake
system through the master cyl i nder.
(5) Perform a fi nal adjustment of the rear brake
shoes and then test dri ve vehi cl e to be sure brakes
are operati ng correctl y and that pedal i s sol i d.
Fig. 28 Pressure Bleeding Cap Installed On Master
Cylinder
Fig. 29 Rear Wheel Cylinder Bleeder Screw
NS BRAKES 5 - 21
MASTER CYLINDER BLEEDING PROCEDURE
CAUTION: When clamping master cylinder in vise,
only clamp master cylinder by its mounting flange,
do not clamp on primary piston, seal\boot or body
of master cylinder.
(1) Cl amp the master cyl i nder i n a vi se usi ng onl y
the mounti ng fl ange (Fi g. 30).
NOTE: Two different size bleeding tubes are used
depending on which type of master cylinder the
vehicle is equipped with. Vehicles equipped with
traction control use a center port master cylinder
with a larger diameter brake tube. Vehicles not
equipped with traction control use a compensating
port master cylinder using a standard 3/16 inch
diameter brake tube. Be sure the correct size bleed-
ing tubes are used when bleeding the master cylin-
der.
(2) I nstal l the Bl eedi ng Tubes, Speci al Tool 6920
for a non tracti on control master cyl i nder or Speci al
Tool 8129 for a tracti on control master cyl i nder on
the master cyl i nder (Fi g. 102). Posi ti on bl eedi ng
tubes so the outl ets of bl eedi ng tubes wi l l be bel ow
surface of brake fl ui d when reservoi r i s fi l l ed to i ts
proper l evel .
(3) Fi l l brake fl ui d reservoi r wi th brake fl ui d con-
formi ng to DOT 3 speci fi cati ons such as Mopar or an
Equi val ent.
(4) Usi ng a wooden dowel , depress push rod sl owl y,
and then al l ow pi stons to return to rel eased posi ti on.
Repeat several ti mes unti l al l ai r bubbl es are
expel l ed from master cyl i nder.
(5) Remove bl eedi ng tubes from master cyl i nder
outl et ports, and then pl ug outl et ports and i nstal l
fi l l cap on reservoi r.
(6) Remove master cyl i nder from vi se.
(7) I nstal l the fi l l er cap from the master cyl i nder
fi l l er neck, on the master cyl i nder fl ui d reservoi r.
(8) I nstal l the master cyl i nder assembl y on the
power brake vacuum booster.
NOTE: Note: It is not necessary to bleed the ABS
hydraulic control unit (HCU) after replacing the
master cylinder. But, the base brake hydraulic sys-
tem must be bled to ensure no air is entered the
hydraulic system when the master cylinder was
removed.
ROTOR MACHINING (FRONT/REAR)
BRAKE ROTOR MACHINING PROCEDURES
Any servi ci ng of the rotor requi res extreme care to
mai ntai n the rotor to wi thi n servi ce tol erances to
ensure proper brake acti on.
I f the rotor surface i s deepl y scored or warped, or
there i s a compl ai nt of brake roughness or brake
pedal pul sati on, the rotor shoul d be resurfaced,
refaced (Fi g. 32) or (Fi g. 33) or repl aced.
NOTE: All rotors have markings for minimum
allowable thickness cast on an un-machined sur-
face of the rotor (Fig. 34) or (Fig. 35).
Thi s marki ng i ncl udes 0.76 mm (0.030 i nch) al l ow-
abl e rotor wear beyond the recommended 0.76 mm
(0.030 i nch) of rotor refaci ng.
The col l ets, shafts and adapters used on the brake
l athe and the beari ng cups i n the rotor MUST be
cl ean and free from any chi ps or contami nati on.
When mounti ng the rotor on the brake l athe, stri ct
attenti on to the brake l athe manufacturers operati ng
i nstructi ons i s requi red.
I f the rotor i s not mounted properl y, the l ateral
runout wi l l be worse after refaci ng or resurfaci ng
than before.
Fig. 30 Master Cylinder Mounted In Vise
Fig. 31 Bleed Tubes Installed On Master Cylinder
5 - 22 BRAKES NS
REFACING BRAKE ROTOR
Refaci ng of the rotor i s not requi red each ti me the
brake pads are repl aced.
When refaci ng a rotor the requi red 0.08 mm (0.003
i nch) TI R (Total I ndi cator Readi ng) and 0.013 mm
(0.0005 i nch) thi ckness vari ati on l i mi ts MUST BE
MAI NTAI NED. Extreme care i n the operati on of
rotor turni ng equi pment i s requi red.
The use of a doubl e straddl e cutter (Fi g. 32) that
machi nes both si des of the rotor at the same ti me i s
hi ghl y recommended.
RESURFACNG BRAKE ROTOR
Thi s operati on can be used when rotor surface i s
rusty, has l i ni ng deposi ts or excessi ve l ateral runout
or thi ckness vari ati on i s evi dent.
A sandi ng rotor attachment (Fi g. 33) wi l l remove
surface contami nati on wi thout removi ng much rotor
materi al .
I t wi l l general l y fol l ow vari ati ons i n thi ckness that
are i n the rotor.
Fig. 32 Refacing Brake Rotor
Fig. 33 Resurfacing Brake Rotor (Final Finish)
Fig. 34 Front Rotor Thickness Markings
Fig. 35 Rear Rotor Thickness Markings
NS BRAKES 5 - 23
BRAKE DRUM MACHINING
Measure the runout and di ameter of the rear brake
usi ng onl y accurate measuri ng equi pment. There
shoul d be no vari ati on i n the drum di ameter greater
than 0.090 mm (0.004 i nch). Drum runout shoul d not
exceed 0.15 mm (0.006 i nch) out of round. I f the
drum runout or di ameter vari ati on exceed these val -
ues the drum shoul d be refaced. For best resul ts i n
el i mi nati ng the i rregul ari ti es that cause brake rough-
ness and surge, the amount of materi al removed dur-
i ng a si ngl e cut shoul d be l i mi ted to 0.13 mm (0.005
i nch). When the enti re braki ng surface has been
cl eaned. A fi nal cut of 0.0254 mm (0.001 i nch) wi l l
assure a good drum surface provi di ng the equi pment
used i s capabl e of the preci si on requi red for resurfac-
i ng brake drums. Deeper cuts are permi ssi bl e for the
sol e purpose of removi ng deep score marks. Do not
reface more than 1.52 mm (0.060 inch) over the
standard drum diameter.
Al l drums wi l l show marki ngs of maxi mum al l ow-
abl e di ameter (Fi g. 36). For exampl e, a drum wi l l
have a marki ng of MAX. DI A. 251.55 mm (9.90 i nch).
Thi s marki ng i ncl udes 0.76 mm (0.030 i nch) for
al l owabl e drum wear beyond the recommended 1.52
mm (0.060 i nch) of drum refaci ng
BRAKE TUBE REPAIR PROCEDURE
CAUTION: When repairing brake chassis lines or
flex hoses, the correct fasteners must be used to
attach the routing clips or hoses to the front sus-
pension cradle. The fasteners used to attach com-
ponents to the front suspension cradle have an
anti-corrosion coating due to the suspension cradle
being made of aluminum. Only Mopar replacement
fasteners with the required anti-corrosion coating
are to be used if a replacement fastener is required
when installing a brake chassis line or flex hose.
Onl y doubl e wal l 4.75mm (3/16 i n.) steel tubi ng
wi th Al -ri ch/ZW-AC al l oy coati ng and the correct tube
nuts are to be used for repl acement of a hydraul i c
brake tube.
NOTE: On vehicles equipped with traction control,
the primary and secondary hydraulic tubes between
the master cylinder and the hydraulic control unit
are 6 mm (15/64 in.). These tubes are also coated
with the Al-rich/ZW-AC alloy and must be replaced
with tubes having the same anti-corrosion coating.
Be sure the correct tube nuts are used for the
replacement of these hydraulic brake tubes.
Care shoul d be taken when repai ri ng brake tubi ng,
to be sure the proper bendi ng and fl ari ng tool s and
procedures are used, to avoi d ki nki ng. Do not route
the tubes agai nst sharp edges, movi ng components or
i nto hot areas. Al l tubes shoul d be properl y attached
wi th recommended retai ni ng cl i ps.
I f the pri mary or secondary brake l i ne from the
master cyl i nder to the ABS Hydraul i c Control Uni t,
or the fl exi bl e brake l i nes between the hydraul i c con-
trol uni t and the proporti oni ng val ve requi re repl ace-
ment only the ori gi nal factory brake l i nes contai ni ng
a fl exi bl e secti on can be used. Thi s i s requi red due to
the movement of the front suspensi on cradl e whi l e
the vehi cl e i s i n moti on.
Usi ng Tubi ng Cutter, Speci al Tool C-3478-A or
equi val ent, cut off damaged seat or tubi ng (Fi g. 37).
Ream out any burrs or rough edges showi ng on
i nsi de of tubi ng (Fi g. 38). Thi s wi l l make the ends of
tubi ng square (Fi g. 38) and ensure better seati ng of
ROTOR REFINISHING LIMITS
Braking Rotor
Rotor Thick-
ness
Minimum Rotor
Thickness
Rotor Thick-
ness Variation
Rotor Run
Out*
Rotor Micro
Finish
Front Rotor 23.87-24.13 mm
.939 -.949 in.
22.4 mm
.881 in.
.013 mm
.0005 in.
.08 mm
.003 in.
15-80 RMS
Rear Rotor 12.75-12.25 mm
.502 -.482 in.
11.25 mm
.443 in.
.013 mm
.0005 in.
.08 mm
.003 in.
15-80 RMS
* TIR Total Indicator Reading (Measured On Vehicle)
Fig. 36 Rear Brake Drum Maximum Diameter
Identification
5 - 24 BRAKES NS
fl ared end tubi ng. PLACE TUBE NUT ON TUB-
ING BEFORE FLARING THE TUBING.
DOUBLE INVERTED TUBING FLARES
To make a doubl e i nverted tubi ng fl are (Fi g. 39)
and (Fi g. 40). Open handl es of Fl ari ng Tool , Speci al
Tool C-4047 or equi val ent. Then rotate jaws of tool
unti l the mati ng jaws of tubi ng si ze are centered
between verti cal posts on tool . Sl owl y cl ose handl es
wi th tubi ng i nserted i n jaws but do not appl y heavy
pressure to handl e as thi s wi l l l ock tubi ng i n pl ace.
Pl ace gauge (Form A) on edge over end of brake
tubi ng. Push tubi ng through jaws unti l end of tubi ng
contacts the recessed notch i n gauge matchi ng the
tubi ng si ze. Squeeze handl es of fl ari ng tool and l ock
tubi ng i n pl ace. Pl ace 3/16 i nch pl ug of gauge (A)
down i n end of tubi ng. Swi ng compressi on di sc over
gauge and center tapered fl ari ng screw i n recess of
di sc. Screw i n unti l pl ug gauge has seated on jaws of
fl ari ng tool . Thi s acti on has started to i nvert the
extended end of the tubi ng. Remove gauge and con-
ti nue to screw down unti l tool i s fi rml y seated i n tub-
i ng. Remove tubi ng from fl ari ng tool and i nspect
seat. Refer to tube routi ng di agrams for proper brake
tube routi ng and cl i p l ocati ons. Repl ace any damaged
tube routi ng cl i ps.
ISO TUBING FLARES
CAUTION: All ISO style tubing flares (Fig. 39) and
(Fig. 40) are of metric dimensions. When performing
any service procedures on vehicles using ISO style
tubing flares, metric size tubing of 4.75 mm MUST
be used with metric ISO tube flaring equipment.
To create a (metri c) I SO styl e tubi ng fl are, Use
Snap-On Fl ari ng Tool TFM-428, or equi val ent. See
(Fi g. 41) and proceed wi th the steps l i sted bel ow. Be
sure to place the tubing nut on the tube before
flaring the tubing.
(1) Careful l y prepare the end of the tubi ng to be
fl ared. Be sure the end of the tubi ng to be fl ared i s
square and al l burrs on the i nsi de of the tubi ng are
removed (Fi g. 38). This preparation is essential to
Fig. 37 Cutting And Flaring Of Brake Fluid Tubing
Fig. 38 Brake Fluid Tube Preparation For Flaring
Fig. 39 Hydraulic Brake Tubing Flare Styles
NS BRAKES 5 - 25
obtain the correct formof a (metric) ISO tubing
flare.
(2) Open jaws of the Fl ari ng Tool . Al i gn the mati ng
si ze jaws of the fl ari ng tool around the si ze of the
tubi ng to be fl ared. Cl ose the jaws of the Fl ari ng Tool
around the tubi ng to keep i t from sl i di ng out of the
fl ari ng tool , but do not l ock the tubi ng i n pl ace. See
(Fi g. 41)
(3) Posi ti on the tubi ng i n the jaws of the Fl ari ng
Tool so that i t i s fl ush wi th the top surface of the
fl ari ng tool bar assembl y. (Fi g. 41) )
(4) I nstal l the correct si ze adaptor for the brake
tubi ng bei ng fl ared, on the feed screw of the yoke
assembl y. Center the yoke and adapter over the end
of the tubi ng. Appl y l ubri cant to the adapter area
that contacts brake tubi ng. Maki ng sure the adapter
pi l ot i s ful l y i nserted i n the end of the brake tubi ng.
Screw i n the feed screw of the yoke assembl y unti l
the adaptor has seated squarel y on the surface of the
bar assembl y (Fi g. 41). Thi s process has created the
(metri c) I SO tubi ng fl are.
PARK BRAKE AUTO ADJUSTER MECHANISM
RELEASE
The park brake pedal mechani sm used i n thi s vehi -
cl e i s desi gned so that the auto adjuster i s not
requi red to be l ocked out when servi ci ng the park
brake pedal and or the park brake cabl es.
Thi s park brake pedal mechani sm i s desi gned so
that the adjuster mechani sm wi l l rotate onl y hal f a
turn when the tensi on i s rel eased from the park
brake cabl e. Thi s el i mi nates the requi rement to l ock
out the automati c adjuster when servi ci ng the park
brake pedal mechani sm and cabl es.
Use the fol l owi ng procedure to rel ease the tensi on
from the park brake cabl es and the auto adjuster i n
the park brake pedal mechani sm.
(1) Grasp the exposed secti on of the front park
brake cabl e and pul l rearward on i t. Whi l e hol di ng
the park brake i n thi s posi ti on, i nstal l a pai r of l ock-
i ng pl i ers on the front park brake cabl e just rearward
of the second body outri gger bracket (Fi g. 42).
(2) Remove the l eft rear and i ntermedi ate park
brake cabl e from the park brake cabl e equal i zer (Fi g.
43).
(3) Remove the equal i zer from the front park
brake cabl e.
Fig. 40 Inverted Double Wall Flare And ISO Flare
Tubing Connections
Fig. 41 Brake Tubing ISO Flaring Process
Fig. 42 Locking Out Automatic Adjuster
5 - 26 BRAKES NS
(4) Remove the l ocki ng pl i ers from the front park
brake cabl e. Thi s wi l l al l ow the adjuster i n the park
brake pedal mechani sm to rotate around to i ts stop.
Thi s wi l l remove the tensi on from the adjuster and
front park brake cabl e.
Use the fol l owi ng procedure to reset the auto
adjuster i n the park brake pedal mechani sm.
(5) Grasp the exposed secti on of the front park
brake cabl e and pul l rearward on i t. Whi l e hol di ng
the park brake i n thi s posi ti on, i nstal l a pai r of l ock-
(6) I nstal l the equal i zer on the front park brake
cabl e.
(7) I nstal l the l eft rear and i ntermedi ate park
brake cabl e i n the correct l ocati on on the park brake
cabl e equal i zer (Fi g. 43).
brake cabl e. Thi s wi l l al l ow the adjuster i n the park
brake pedal mechani sm to tensi on the park brake
cabl es.
(9) Appl y and rel ease the park brake pedal one
ti me. Thi s wi l l seat the park brake cabl es and al l ow
the auto adjuster i n the park brake pedal mechani sm
to correctl y tensi on the park brake cabl es.
WHEEL AND TIRE INSTALLATION
To i nstal l the wheel and ti re assembl y, fi rst posi -
ti on i t properl y on the mounti ng surface usi ng the
hub pi l ot as a gui de. Then progressi vel y ti ghten the
l ug nuts i n the proper sequence to hal f of the
requi red torque. Fi nal l y ti ghten the l ug nuts i n the
proper sequence to 129 Nm (95 ft. l bs.). Never use
oi l or grease on studs or nuts.
FRONT DISC BRAKE CALIPER
SERVICE PRECAUTIONS
WARNING: ALTHOUGH FACTORY INSTALLED
BRAKE LININGS ARE MADE FROM ASBESTOS
FREE MATERIALS, SOME AFTER MARKET BRAKE
LINING MAY CONTAIN ASBESTOS. THIS SHOULD
BE TAKEN INTO ACCOUNT WHEN SERVICING A
VEHICLES BRAKE SYSTEM, WHEN AFTERMARKET
BRAKE LININGS MAY HAVE BEEN INSTALLED ON
THE VEHICLE. ALWAYS WEAR A RESPIRATOR
WHEN CLEANING BRAKE COMPONENTS AS
ASBESTOS CAN CAUSE SERIOUS BODILY HARM
SUCH AS ASBESTOSIS AND OR CANCER. NEVER
CLEAN BRAKE COMPONENTS BY USING COM-
PRESSED AIR, USE ONLY A VACUUM CLEANER
SPECIFICALLY DESIGNED FOR THE REMOVAL OF
BRAKE DUST. IF A VACUUM CLEANER IS NOT
AVAILABLE, CLEAN BRAKE PARTS USING ONLY
WATERDAMPENED SHOP TOWELS. DO NOT CRE-
ATE BRAKELINING DUST BY SANDING BRAKE LIN-
INGS WHEN SERVICING A VEHICLE. DISPOSE OF
ALL DUST AND DIRT SUSPECTED OF CONTAINING
ASBESTOS FIBERS USING ONLY SEALED AIR-
TIGHT BAGS OR CONTAINERS. FOLLOW ALL REC-
OMMENDED SAFETY PRACTICES PRESCRIBED BY
THE OCCUPATIONAL SAFETY AND HEALTH ADMIN-
ISTRATION (OSHA) AND THE ENVIRONMENTAL
PROTECTION AGENCY (EPA), FOR HANDLING AND
DISPOSAL OF PRODUCTS CONTAINING ASBES-
TOS.
CAUTION: During service procedures, grease or
any other foreign material must be kept off brake
shoe assemblies, and braking surfaces of brake
drum and external surfaces of hub/bearing assem-
bly.
REMOVE
nance group of thi s servi ce manual .
(2) Remove front wheel and ti re assembl i es.
Fig. 43 Park Brake Cable Attachment To Equalizer
NS BRAKES 5 - 27
(3) Remove the 2 cal i per to steeri ng knuckl e gui de
pi n bol ts (Fi g. 44).
(4) Remove cal i per from steeri ng knuckl e, by fi rst
rotati ng free end of cal i per away from steeri ng
knuckl e. Then sl i de opposi te end of cal i per out from
under machi ned abutment on steeri ng knuckl e (Fi g.
45).
(5) Support cal i per fi rml y to prevent wei ght of cal -
i per from bei ng supported by the brake fl ui d fl ex
hose. Supporti ng wei ght of cal i per by the brake fl ui d
fl ex hose, can damage the fl exi bl e brake hose (Fi g.
46).
INSTALL
(1) Lubri cate both steeri ng knuckl e abutments
wi th a l i beral amount of Mopar Mul ti purpose Lubri -
cant, or equi val ent.
CAUTION: Use care when installing the caliper
assembly onto the steering knuckle, so the seals on
the caliper guide pin bushings do not get damaged
by the steering knuckle bosses.
(2) Careful l y posi ti on cal i per and brake pad
assembl i es over brake rotor by hooki ng l ower or
upper end of cal i per over the machi ned abutment on
steeri ng knuckl e (Fi g. 45). Then rotate cal i per i nto
posi ti on at the top of the steeri ng knuckl e (Fi g. 45).
Make sure that cal i per gui de pi n bol ts, bushi ngs and
sl eeves are cl ear of the steeri ng knuckl e bosses.
(3) I nstal l the cal i per gui de pi n bol ts (Fi g. 44) and
ti ghten to a torque of 41 Nm (40 ft. l bs.). Extreme
caution should be taken not to cross thread the
caliper guide pin bolts.
(4) I nstal l the wheel and ti re assembl y.
(5) Usi ng a torque wrench, ti ghten the wheel
mounti ng stud nuts i n proper sequence unti l al l nuts
are torqued to hal f speci fi cati on. Then repeat the
ti ghteni ng sequence to the ful l speci fi ed torque of 135
Nm (100 ft. l bs.).
(6) Remove jackstands or l ower hoi st.
(7) Before moving vehicle, pump the brake
pedal several times to insure the vehicle has a
firm brake pedal.
REAR DISC BRAKE CALIPER
Duri ng servi ce procedures, grease or any other for-
ei gn materi al must be kept off brake shoe assem-
bl i es, and braki ng surfaces of rotor.
Handl i ng of the rotor and cal i per, must be done i n
such a way as to avoi d damage to the rotor and
scratchi ng or ni cki ng of l i ni ng on the brake shoes.
I f i nspecti on reveal s that the cal i per pi ston seal i s
l eaki ng, i t MUST be repl aced i mmedi atel y.
Duri ng removal and i nstal l ati on of a wheel and
ti re assembl y, use care not to stri ke the cal i per.
Fig. 44 Removing Caliper Guide Pin Bolts
Fig. 45 Caliper Assembly Mounting On Steering
Knuckle (Typical)
Fig. 46 Storing Front Disc Brake Caliper
5 - 28 BRAKES NS
REMOVE
nance secti on of thi s manual .
(2) Remove rear wheel and ti re assembl i es from
vehi cl e.
(3) Remove the di sc brake cal i per to adapter gui de
(4) Remove rear cal i per from adapter usi ng the fol -
l owi ng procedure. Fi rst rotate rear of cal i per up from
the adapter. Then pul l the front of the cal i per and
the outboard brake shoe anti -rattl e cl i p out from
under the front abutment on the adapter (Fi g. 48).
(5) Support cal i per to prevent the wei ght of the
cal i per from damagi ng the fl exi bl e brake hose (Fi g.
49).
INSTALL
NOTE: Step 1 below is only required when install-
ing the disc brake caliper after new brake shoes
have been installed.
(1) Compl etel y retract cal i per pi ston back i nto pi s-
ton bore of cal i per assembl y.
(2) Lubri cate both adapter abutments wi th a l i b-
eral amount of Mopar Mul ti purpose Lubri cant, or
equi val ent.
(3) I f removed, i nstal l the rear rotor on the hub,
maki ng sure i t i s squarel y seated on the face of the
hub.
assembly onto the adapter, so the caliper guide pin
bushings do not get damaged by the mounting
bosses.
(4) Careful l y l ower cal i per and brake shoes over
rotor and onto the adapter usi ng the reverse proce-
dure for removal (Fi g. 48).
CAUTION: When installing guide pin bolts extreme
caution should be taken not to crossthread the cal-
iper guide pin bolts.
(5) I nstal l the cal i per gui de pi n bol ts. Ti ghten the
gui de pi n bol ts to a torque of 22 Nm (192 i n. l bs.).
(7) Ti ghten the wheel mounti ng stud nuts i n
proper sequence unti l al l nuts are torqued to hal f
CAUTION: Before moving vehicle, pump the brake
pedal several times to insure the vehicle has a firm
brake pedal to adequately stop vehicle.
Fig. 48 Removing / Installing Caliper
Fig. 49 Correctly Supported Caliper
NS BRAKES 5 - 29
(9) Road test the vehi cl e and make several stops to
wear off any forei gn materi al on the brakes and to
seat the brake shoe l i ni ngs.
FRONT DISC BRAKE PADS
REMOVE
FREE MATERIALS, SOME AFTERMARKET BRAKE
LININGS MAY CONTAIN ASBESTOS. THIS SHOULD
TOS.
CAUTION: During service procedures, grease or
any other foreign material must be kept off brake
shoe assemblies, and braking surfaces of brake
drum and external surfaces of hub/bearing assem-
bly.
(1) Remove outboard brake pad, by pryi ng the pad
retai ni ng cl i p over rai sed area on cal i per (Fi g. 50).
Then sl i de the pad down and off the cal i per.
(2) Pul l i nboard brake pad away from pi ston, unti l
retai ni ng cl i p on brake pad i s free from cavi ty i n cal -
i per pi ston (Fi g. 51).
INSTALL
ton bore of cal i per assembl y. Thi s i s requi red for cal -
i per i nstal l ati on wi th new brake pad assembl i es.
(2) Remove the protecti ve paper from the noi se
suppressi on gasket on both the i nner and outer brake
pad assembl i es (i f equi pped).
NOTE: The inboard and outboard brake pads are
not common, refer to (Fig. 52) for inboard and out-
board brake pad assembly identification.
(3) I nstal l the new i nboard brake pad assembl y
i nto the cal i per pi ston by fi rml y pressi ng i nto pi ston
bore (Fi g. 53). Be sure i nboard brake pad assembl y i s
posi ti oned squarel y agai nst face of cal i per pi ston.
(4) Sl i de the new outboard brake pad assembl y
onto the cal i per assembl y (Fi g. 54).
Fig. 50 Removing Outboard Brake Pad From Caliper
Fig. 51 Removing Inboard Brake Pad From Piston
5 - 30 BRAKES NS
REAR DISC BRAKE SHOES
BRAKELININGS ARE MADE FROM ASBESTOS
FREE MATERIALS, SOME AFTER MARKET BRAKE-
BRAKELININGS MAY HAVE BEEN INSTALLED ON
WATER DAMPENED SHOP TOWELS. DO NOT CRE-
TOS.
Duri ng servi ce procedures, grease or any other for-
ei gn materi al must be kept off brake shoe assem-
bl i es, and braki ng surfaces of brake drum and
external surfaces of hub/beari ng assembl y.
Handl i ng of the braki ng di sc and cal i per i s to be
done i n such a way as to avoi d deformati on of the
di sc and scratchi ng or ni cki ng of brake l i ni ngs.
I f i nspecti on reveal s that the square secti oned cal -
i per pi ston seal i s worn or damaged, i t MUST be
repl aced i mmedi atel y.
Duri ng removal and i nstal l ati on of a wheel and
ti re assembl y, use care not to stri ke the cal i per.
REMOVE
(2) Remove rear wheel and ti re assembl i es from
vehi cl e.
(3) Remove the cal i per to adapter gui de pi n bol ts
(Fi g. 55).
(4) Remove rear cal i per from adapter usi ng the fol -
l owi ng procedure. Fi rst rotate rear of cal i per up from
the adapter. Then pul l the front of the cal i per and
the outboard brake shoe anti -rattl e cl i p out from
57).
Fig. 52 Front Brake Pad Assembly Identification
Fig. 53 Installing Inboard Brake Pad Assembly
Fig. 54 Installing Outboard Brake Shoe Assembly
NS BRAKES 5 - 31
(6) Remove the rear rotor from the hub by pul l i ng
i t strai ght off the wheel mounti ng studs.
(7) Remove the outboard brake shoe from the cal i -
per. Brake shoe i s removed by pryi ng brake shoe
retai ni ng cl i p over rai sed area on cal i per and sl i di ng
the brake shoe off the cal i per.
(8) Remove i nboard brake shoe from cal i per.
I nboard brake shoe i s removed by pul l i ng i t out of
the cal i per pi ston, unti l the retai ni ng cl i p i s free of
the pi ston (Fi g. 58).
CALIPER INSPECTION
Check for pi ston seal l eaks (brake fl ui d i n and
around boot area and i nboard l i ni ng) and for any
ruptures of the pi ston dust boot. I f boot i s damaged,
or fl ui d l eak i s vi si bl e, di sassembl e cal i per assembl y
and i nstal l a new seal and boot, (and pi ston i f
scored). Refer to procedures ti tl ed Di sc Brake Cal i per
Di sassembl y.
Check the cal i per dust boot and cal i per pi n bush-
i ngs to determi ne i f they are i n good condi ti on.
Repl ace i f they are damaged, dry, or found to be bri t-
tl e. Refer to Cl eani ng And I nspecti on Of Brake Cal i -
per.
INSTALL
NOTE: Step 1 below is only required when install-
ing a caliper after new brake shoes have been
installed.
ton bore of cal i per assembl y.
(2) Lubri cate both adapter abutments wi th a l i b-
eral amount of Mopar Mul ti purpose Lubri cant, or
equi val ent.
(3) I f removed, i nstal l the rear rotor on the hub,
maki ng sure i t i s squarel y seated on the face of the
hub.
(4) I nstal l the i nboard brake shoe i nto the cal i per
pi ston by fi rml y pressi ng i t i nto the pi ston bore usi ng
your thumbs. Be sure i nboard brake shoe i s posi -
ti oned squarel y agai nst the face of the cal i per pi ston
(Fi g. 59).
Fig. 55 Caliper Guide Pin Bolts
Fig. 58 Removing Inboard Brake Shoe
5 - 32 BRAKES NS
(5) I nstal l the outboard brake shoe on the di sc
brake cal i per
assembly onto the adapter, so the caliper guide pin
bushings do not get damaged by the mounting
bosses.
rotor and onto adapter, reversi ng the removal proce-
dure (Fi g. 56)
CAUTION: When installing the caliper guide pin
bolts extreme caution should be taken not to
crossthread the guide pin bolts.
(7) I nstal l the cal i per gui de pi n bol ts. Ti ghten the
gui de pi n bol ts to a torque of 22 Nm (192 i n. l bs.).
brake pedal to adequately stop the vehicle.
(11) Road test the vehi cl e and make several stops
to wear off any forei gn materi al on the brakes and to
REAR BRAKE DRUM
REMOVE
(1) Remove the ti re and wheel assembl y from the
vehi cl e
(2) Remove the rear brake shoe adjusti ng hol e
cover pl ug.
(3) I nsert a thi n screwdri ver i nto brake adjusti ng
hol e and hol d adjusti ng l ever away from notches of
adjusti ng screw star wheel .
(4) I nsert Tool C-3784 i nto brake adjusti ng hol e
and engage notches of brake adjusti ng screw star
wheel . Rel ease brake adjustment by pryi ng down
wi th adjusti ng tool .
(5) Remove rear brake drum from rear hub/bear-
i ng assembl y.
INSTALL
(1) Adjust brake shoes assembl i es so as not to
i nterfere wi th brake drum i nstal l ati on.
(2) I nstal l the rear brake drums on the hubs.
(3) Adjust rear brake shoes per Adjusti ng Rear
Brakes procedure i n the servi ce adjustments secti on
(4) I nstal l the removed park brake cabl e back on
the park brake cabl e equal i zer (Fi g. 60)
(5) I nstal l wheel and ti re.
Fig. 59 Installing Inboard Brake Shoe
NS BRAKES 5 - 33
REAR DRUM BRAKE SHOES
REMOVE
FREE MATERIALS, SOME AFTERMARKET BRAK-
ATE BRAKE LINING DUST BY SANDING BRAKE
LININGS WHEN SERVICING A VEHICLE. DISPOSE
OF ALL DUST AND DIRT SUSPECTED OF CONTAIN-
ING ASBESTOS FIBERS USING ONLY SEALED AIR-
TIGHT BAGS OR CONTAINERS. FOLLOW ALL
RECOMMENDED SAFETY PRACTICES PRE-
SCRIBED BY THE OCCUPATIONAL SAFETY AND
HEALTH ADMINISTRATION (OSHA) AND THE ENVI-
RONMENTAL PROTECTION AGENCY (EPA), FOR
HANDLING AND DISPOSAL OF PRODUCTS CON-
TAINING ASBESTOS.
(2) Remove the rear wheel and ti re assembl i es
from the vehi cl e.
(3) Remove rear brake drum to hub retai ni ng nuts
(i f equi pped). Then remove rear brake drums from
hub and beari ng assembl i es.
NOTE: When creating slack in the park brake
cables by locking out the automatic adjuster, (Fig.
61) be sure that the park brake pedal is in the
released (most upward) position.
(4) Create sl ack i n the rear park brake cabl es.
Sl ack i s created by grabbi ng exposed secti on of front
park brake cabl e and pul l i ng i t down and rearward.
Sl ack i s mai ntai ned i n the park brake cabl e by
i nstal l i ng a pai r of l ocki ng pl i ers on the park brake
cabl e just rearward of only the rear body outri gger
bracket. (Fi g. 61)
(5) Remove adjustment l ever spri ng (Fi g. 62) from
adjustment l ever and front brake shoe.
(6) Remove adjustment l ever (Fi g. 63) from l eadi ng
brake shoe.
Fig. 61 Locked Out Park Brake Automatic Adjuster
Fig. 62 Adjustment Lever Actuating Spring
Fig. 63 Adjustment Lever
5 - 34 BRAKES NS
(7) Remove the brake shoe to brake shoe l ower
return spri ngs (Fi g. 64) and (Fi g. 65).
(8) Remove the tensi on cl i p (Fi g. 66) attachi ng the
upper return spri ng to the automati c adjuster assem-
bl y.
(9) Remove the brake shoe to brake shoe upper
return spri ng (Fi g. 67).
(10) Remove the trai l i ng brake shoe assembl y to
brake support pl ate hol d down spri ng and pi n (Fi g.
68) from the brake shoe assembl y.
(11) Remove the trai l i ng brake shoe assembl y from
the brake support pl ate, park brake actuati ng l ever
and park brake actuati ng strut (Fi g. 69). Remove the
automati c adjuster assembl y from the l eadi ng brake
shoe.
(12) Remove the l eadi ng brake shoe assembl y to
brake support pl ate hol d down spri ng and pi n (Fi g.
70) from the brake shoe. Remove the l eadi ng brake
shoe from the brake support pl ate.
(13) Remove the park brake actuator (Fi g. 71)
from the l eadi ng brake shoe and transfer to the
repl acement brake shoe.
Fig. 64 Remove/Install Brake Shoe Lower Return
Spring
Fig. 65 Brake Shoe Lower Return Spring
Fig. 66 Tension Clip Attachment To Adjuster
Fig. 67 Brake Shoe Upper Return Spring
Fig. 68 Trailing Brake Shoe Hold Down Spring And
Pin
NS BRAKES 5 - 35
INSTALL
(1) Lubri cate the ei ght shoe contact areas on the
support pl ate and anchor, (Fi g. 72) usi ng the
requi red speci al Mopar Brake Lubri cant, P/N
4796269.
(2) I nstal l l eadi ng brake shoe on brake support
pl ate. I nstal l the l eadi ng brake shoe hol d down
spri ng and pi n (Fi g. 70) on the brake shoe.
(3) I nstal l the park brake actuator strut (Fi g. 73)
on the l eadi ng brake shoe. Then i nstal l the park
brake actuator l ever on the strut (Fi g. 73).
(4) I nstal l the automati c adjuster screw on the
l eadi ng brake shoe. Then i nstal l the trai l i ng brake
shoe on the park brake actuati ng l ever and park
brake actuati ng strut (Fi g. 69). Posi ti on trai l i ng
brake shoe on brake support pl ate.
(5) I nstal l the brake shoe hol d down pi n and
spri ng on the trai l i ng brake shoe (Fi g. 68).
(6) I nstal l the brake shoe to brake shoe upper
return spri ng (Fi g. 67).
Fig. 69 Trailing Brake Shoe Removal/Installation
Fig. 70 Leading Brake Shoe Hold Down Spring And
Pin
Fig. 71 Park Brake Actuator Plate
Fig. 72 Brake Support Plate Contact Areas
Fig. 73 Park Brake Components Assembled On
Leading Brake Shoe
5 - 36 BRAKES NS
CAUTION: When installing the tension clip on the
automatic adjuster, it must be located on only the
threaded area of the adjuster assembly (Fig. 66). If
it is located on a non-threaded area of the adjuster,
the function of the automatic adjuster will be
affected.
(7) I nstal l the tensi on cl i p (Fi g. 66) attachi ng the
upper return spri ng to the automati c adjuster assem-
bl y.
(8) I nstal l the brake shoe to brake shoe l ower
return spri ngs on the brake shoes (Fi g. 64) and (Fi g.
65).
(9) I nstal l automati c adjustment l ever on the l ead-
i ng brake shoe of the rear brake assembl y (Fi g. 63).
(10) I nstal l the actuati ng spri ng on the automati c
adjustment l ever and l eadi ng brake shoe assembl y
(Fi g. 62).
(11) Veri fy that the automati c adjuster l ever has
posi ti ve contact wi th the star wheel on the automati c
adjuster assembl y.
(12) When al l components of both rear brake
assembl i es are correctl y and ful l y i nstal l ed, remove
the l ocki ng pl i ers from the front park brake cabl e.
(13) Adjust brake shoes assembl i es so as not to
i nterfere wi th brake drum i nstal l ati on.
(14) I nstal l the rear brake drums on the hubs.
(15) Adjust rear brake shoes per Adjusti ng Rear
Brakes procedure i n the servi ce adjustments secti on
(17) Push the park brake pedal to the fl oor once
and rel ease pedal . Thi s wi l l automati cal l y remove the
sl ack from and correctl y adjust the park brake
cabl es.
(19) Road test vehi cl e. The automati c adjuster wi l l
conti nue the brake adjustment duri ng the road test
of the vehi cl e.
BRAKE SUPPORT PLATE (REAR DRUM BRAKES)
REMOVE
ual for requi red l i fti ng procedure.
(2) Remove wheel and ti re.
(3) Remove brake drum from hub/beari ng.
(4) Remove brake shoes from brake support pl ate.
Refer to Rear Brake Shoe Removal i n the removal
and i nstal l ati on secti on i n thi s group of the servi ce
manual for the requi red procedure.
(5) Di sconnect the park brake cabl e from the park
brake actuati on l ever.
(6) Remove the rear wheel speed sensor from the
rear hub/beari ng fl ange (Fi g. 74). Thi s wi l l prevent
damage to the speed sensor duri ng removal and
i nstal l ati on of the hub/beari ng. The rear wheel
speed sensor bolts to the hub/bearing. It can
not be removed unless the speed sensor is
removed first.
CAUTION: When working in the area of the rear
hub/bearing and when removing it from the rear
axle, care must be used so the teeth on the tone
wheel are not damaged. Damage to the teeth on the
tone wheel will result in false ABS cycling and cor-
rosion of the tone wheel.
(7) Remove the 4 bol ts (Fi g. 75) attachi ng the hub/
beari ng to the fl ange of the rear axl e .
Fig. 74 Rear Wheel Speed Sensor
Fig. 75 Rear Hub/Bearing Mounting Bolts
NS BRAKES 5 - 37
CAUTION: Corrosion may occur between the hub/
bearing and the axle. If this occurs the hub/bearing
will be difficult to remove from the axle. If the hub/
bearing will not come out of the axle by pulling on
it by hand, do not pound on the hub/bearing to
remove it from the axle. Pounding on the hub/bear-
ing to remove it from the axle will damage the hub/
bearing. This damage will result in noise or failure
of the bearing.
(8) I f hub/beari ng cannot be removed from the axl e
by hand, use Remover Speci al Tool 8214 (Fi g. 76) and
fol l owi ng procedure to press the hub/beari ng out of
the axl e.
(a) Pl ace Speci al Tool 8214-1 over tone wheel
and agai nst cast fl ange of hub/beari ng (Fi g. 76)
(b) Put a dab of grease i n the bol t pi l ot hol e on
the back of Speci al Tool 8214-1.
(c) I nsert Speci al Tool 8214-2 i nto the hol e i n the
bottom of the end casti ng on the axl e (Fi g. 76).
Speci al Tool 8214-2 shoul d be agai nst and sup-
ported by the axl e pl ate (Fi g. 76) when pressi ng
the wheel beari ng out of the axl e.If Special Tool
8214-2 will not fit into the hole in the end
casting, file or grind the flashing from the
hole until tool fits properly.
(d) Al i gn bol t i n Speci al Tool 8214-2 wi th pi l ot
hol e i n Speci al Tool 8214-1. Ti ghten bol t agai nst
Speci al Tool 8214-1.
(e) Press hub/beari ng out of axl e by conti nui ng
to ti ghten bol t i n Speci al Tool 8214-2 agai nst Spe-
ci al Tool 8214-1.
(9) Remove the hub/beari ng from the rear axl e and
brake support pl ate (Fi g. 77).
(10) Usi ng a sui tabl e tool such as a 14 mm box
wrench (Fi g. 78) or an ai rcraft type hose cl amp, com-
press the fl ared l egs on park brake cabl e retai ner.
Then pul l the park brake cabl e out of brake support
pl ate.
(11) Lower vehi cl e enough to access the brake
pedal .
(12) Usi ng a brake pedal depressor, move brake
pedal to a posi ti on past i ts fi rst 1 i nch of travel . Thi s
wi l l prevent brake fl ui d from drai ni ng out of master
cyl i nder when brake tube i s remove from wheel cyl -
i nder.
(13) Rai se vehi cl e.
(14) Di sconnect brake tube from wheel cyl i nder
(Fi g. 79).
(15) Remove the 2 bol ts attachi ng the wheel cyl i n-
der to the brake support pl ate (Fi g. 79).
(16) Remove the wheel cyl i nder from the brake
support pl ate.
(17) Remove the rear brake support pl ate from the
rear axl e.
Fig. 76 Special Tool 8214 Installed
Fig. 77 Hub/Bearing Removal And Installation On
Axle
Fig. 78 Removing Park Brake Cable From Brake
Support Plate
5 - 38 BRAKES NS
INSTALL
(1) I nstal l the 4 hub/beari ng to axl e mounti ng
bol ts i nto the mounti ng hol es i n the fl ange of the
rear axl e.
(2) I nstal l the rear brake support pl ate on the 4
mounti ng bol ts i nstal l ed i n the fl ange of the rear axl e
(Fi g. 80).
NOTE: When installing the hub/bearing on the rear
axle, the bearing is to be installed with the thick
bearing mounting flange (Fig. 77) pointing down.
(3) Al i gn the rear hub/beari ng wi th the 4 mount-
i ng bol ts and start mounti ng bol ts i nto hub/beari ng.
Ti ghten the 4 bol ts i n a cri ss-cross pattern unti l the
hub/beari ng and brake support pl ate i s ful l y and
squarel y seated onto fl ange of rear axl e.
(4) Ti ghten the 4 hub/beari ng mounti ng bol ts (Fi g.
75) to a torque of 129 Nm (95 ft. l bs.)
(5) Appl y seal ant such as Mopar Gasket-I n-A-Tube
or an equi val ent around the wheel cyl i nder openi ng
i n the brake support pl ate.
(6) I nstal l wheel cyl i nder onto brake support and
ti ghten the wheel cyl i nder to brake support pl ate
attachi ng bol ts (Fi g. 79) to 8 Nm (75 i n. l bs.).
(7) I nstal l brake tube (Fi g. 79) on rear wheel cyl -
i nder. Ti ghten tube nut to a torque of 16 Nm (142 i n.
l bs.).
(8) I nstal l the rear wheel speed sensor on the rear
hub/beari ng fl ange (Fi g. 74). I nstal l the speed sensor
attachi ng bol t and ti ghten to a torque of 12 Nm (105
i n. l bs.).
(9) I nstal l the rear park brake cabl e i nto i ts
mounti ng hol e i n the rear brake support pl ate.
(10) I nstal l the park brake cabl e on the park brake
actuati on l ever.
(11) I nstal l the rear brake shoes on the brake sup-
port pl ate. Refer to Brake Shoe Servi ce i n thi s sec-
ti on of the servi ce manual for the proper brake shoe
i nstal l ati on procedure.
(12) I nstal l brake drum onto hub/beari ng.
(14) Ti ghten wheel stud nuts to 129 Nm (95 ft.
l bs.).
(15) Adjust the rear brakes, (See Adjusti ng Servi ce
Brakes) i n Servi ce Adjustments secti on i n thi s group
(16) Bl eed the enti re brake system. See Bl eedi ng
Brake System i n the Servi ce Procedures secti on i n
thi s group of the servi ce manual .
REAR BRAKE WHEEL CYLINDER
REMOVE
(1) I n case of a l eak, remove brake shoes, (repl ace
i f soaked wi th grease or brake fl ui d.)
(2) Di sconnect the rear brake hydraul i c tube from
the wheel cyl i nder (Fi g. 81).
Fig. 79 Rear Wheel Cylinder Mounting Bolts And
Brake Tube
Fig. 80 Brake Support Plate Mounted On Bearing
Attaching Bolts
Fig. 81 Brake Hydraulic Tube At Wheel Cylinder
NS BRAKES 5 - 39
(3) Remove the rear wheel cyl i nder attachi ng bol ts
(Fi g. 81). Then pul l wheel cyl i nder assembl y off the
brake support pl ate.
INSTALL
(1) Appl y Mopar Gasket I n-A-Tube or equi val ent
seal ant around wheel cyl i nder mounti ng surface i n
brake support pl ate.
(2) I nstal l wheel cyl i nder onto brake support, and
ti ghten the wheel cyl i nder to brake support pl ate
attachi ng bol ts (Fi g. 81) to 8 Nm (75 i n. l bs.).
(3) Attach hydraul i c brake tube to wheel cyl i nder,
(Fi g. 81) and ti ghten tube to wheel cyl i nder fi tti ng to
16 Nm (142 i n. l bs.).
(4) I nstal l brake shoes on support pl ate.
(5) I nstal l rear brake drum onto rear hub. I nstal l
rear wheel and ti re assembl y, ti ghten wheel stud
nuts to 129 Nm (95 ft. l bs.).
(7) Bl eed the enti re brake system. See (Bl eedi ng
Brake System) i n Servi ce Adjustments secti on i n thi s
group of the servi ce manual .
HUB/BEARING
FRONT WHEEL DRIVE
REMOVE
(2) Remove wheel and ti re.
(3) Remove brake drum from hub/beari ng.
(4) Remove rear wheel speed sensor from rear hub/
beari ng (Fi g. 82). Thi s wi l l prevent damage to the
speed sensor duri ng removal and i nstal l ati on of the
hub/beari ng. The rear wheel speed sensor bolts
to the hub/bearing. It can not be removed
unless the speed sensor is removed first.
CAUTION: When working in the area of the rear
hub/bearing and when removing it from the rear
axle, care must be used so the teeth on the tone
wheel are not damaged. Damage to the teeth on the
tone wheel will result in false ABS cycling and cor-
rosion of the tone wheel.
beari ng to the rear axl e.
of the bearing.
(6) I f hub/beari ng cannot be removed from the axl e
by hand, use Remover Speci al Tool 8214 (Fi g. 84) and
fol l owi ng procedure to press the hub/beari ng out of
the axl e.
(a) Pl ace Speci al Tool 8214-1 over tone wheel
and agai nst cast fl ange of hub/beari ng (Fi g. 84)
(b) Put a dab of grease i n the bol t pi l ot hol e on
the back of Speci al Tool 8214-1.
(c) I nsert Speci al Tool 8214-2 i nto the hol e i n the
bottom of the end casti ng on the axl e (Fi g. 84).
Speci al Tool 8214-2 shoul d be agai nst and sup-
ported by the axl e pl ate (Fi g. 84) when pressi ng
the wheel beari ng out of the axl e. If Special Tool
8214-2 will not fit into the hole in the end
casting, file or grind the flashing from the
hole until tool fits properly.
5 - 40 BRAKES NS
(d) Al i gn bol t i n Speci al Tool 8214-2 wi th pi l ot
hol e i n Speci al Tool 8214-1. Ti ghten bol t agai nst
Speci al Tool 8214-1.
(e) Press hub/beari ng out of axl e by conti nui ng
to ti ghten bol t i n Speci al Tool 8214-2 agai nst Spe-
ci al Tool 8214-1.
(7) Remove the hub/beari ng from the rear axl e and
brake support pl ate (Fi g. 85).
INSTALL
(1) I nstal l the 4 hub/beari ng to axl e mounti ng
bol ts i nto the hol es i n the fl ange of the rear axl e.
mounti ng bol ts i nstal l ed i n the fl ange of the rear
axl e.
(3) Al i gn the rear hub/beari ng wi th the 4 mount-
i ng bol ts and start mounti ng bol ts i nto hub/beari ng.
Ti ghten the 4 bol ts i n a cri ss-cross pattern unti l the
hub/beari ng and brake support pl ate i s ful l y and
squarel y seated onto fl ange of rear axl e.
i n. l bs.).
(6) I nstal l brake drum on hub/beari ng.
(8) Ti ghten the wheel stud nuts i n the proper
sequence to a torque of 129 Nm (95 ft. l bs.).
ALL WHEEL DRIVE
REMOVE
(1) Set the parki ng brake. The parking brake is
set to keep the hub/bearing and axle shaft from
rotating when loosening the hub nut.
(3) Remove the wheel /ti re.
(4) Remove the cotter pi n and nut retai ner (Fi g.
86) from the stub shaft of the outer C/V joi nt.
(5) Remove the spri ng washer (Fi g. 87) from the
stub shaft of the outer C/V joi nt.
(6) Remove the hub nut and washer (Fi g. 88) from
the stub shaft of the outer C/V joi nt.
(7) Remove the 6 bol ts (Fi g. 89) mounti ng the
dri veshaft i nner joi nt to the output shaft of the rear
dri ve l i ne modul e.
(8) Remove the rear wheel speed sensor (Fi g. 90)
from the rear hub/beari ng.
(9) Rel ease the parki ng brake.
(10) Remove the di sc brake cal i per to adapter
gui de pi n bol ts (Fi g. 91).
(11) Remove rear cal i per from adapter usi ng the
fol l owi ng procedure. Fi rst rotate rear of cal i per up
Fig. 84 Special Tool 8214 Installed
Fig. 85 Removing Rear Hub/Bearing From Axle
Fig. 86 Cotter Pin And Nut Retainer
NS BRAKES 5 - 41
from the adapter. Then pul l the front of the cal i per
and the outboard brake shoe anti -rattl e cl i p out from
93).
(13) Remove the rotor from the hub/beari ng.
Fig. 87 Spring Washer
Fig. 88 Hub Nut And Washer
Fig. 89 Driveshaft Attachment To Driveline Module
Fig. 90 Wheel Speed Sensor
Fig. 91 Caliper Guide Pin Bolts
5 - 42 BRAKES NS
(14) Remove dri veshaft from rear dri ve l i ne mod-
ul e and hub/beari ng. Dri veshaft i s removed by fi rst
compressi ng the i nner joi nt on the dri veshaft and
removi ng i t from the dri ve l i ne modul e. Then, sl i de
the outer joi nt of the dri veshaft out of the hub/bear-
i ng.
(15) Remove the hub/beari ng to axl e mounti ng
bol ts (Fi g. 94).
of the hub/bearing. To remove a hub/bearing which
is corroded to the axle, lightly tap the disc brake
caliper adapter using a soft faced hammer. This will
remove both the disc brake caliper adapter and
hub/bearing from the axle. The hub/bearing will
then need to be removed from the caliper adapter.
(16) Remove the hub/beari ng from the axl e. (Fi g.
95).
(17) I f the di sc brake cal i per adapter and hub/
beari ng were removed as an assembl y from the axl e
and the hub/beari ng cannot be removed from the
adapter by hand, use the fol l owi ng procedure to
remove i t from the adapter. Wi th a hel per supporti ng
the cal i per adapter i n hi s hands, posi ti on Remover,
Speci al Tool 8214-1 on the cast housi ng of hub/bear-
i ng (Fi g. 96). Do not position special tool on
inner race of hub/bearing. Li ghtl y stri ke Remover,
Speci al Tool 8214-1 wi th a hammer to remove the
beari ng.
INSTALL
(1) I nstal l hub/beari ng on end of axl e. (Fi g. 95).
(2) I nstal l the hub/beari ng mounti ng bol ts. I n a
progressi ve cri ss-cross pattern, ti ghten the 4 hub/
beari ng mounti ng bol ts (Fi g. 94) unti l the di sc brake
Fig. 94 Hub/Bearing Mounting Bolts
Fig. 95 Hub/Bearing Removal And Installation
Fig. 96 Hub/Bearing Removal From Caliper Adapter
NS BRAKES 5 - 43
cal i per adapter and hub/beari ng are squarel y seated
agai nst the axl e. Then ti ghten the hub/beari ng
mounti ng bol ts to a torque of 129 Nm (95 ft. l bs.).
(3) I nstal l dri veshaft i n hub/beari ng and on output
shaft of rear dri ve l i ne modul e. Dri veshaft i s
i nstal l ed by fi rst sl i di ng the outer joi nt of the dri ve-
shaft i nto the hub/beari ng and then compressi ng the
i nner joi nt on the dri veshaft and i nstal l i ng i t on the
output shaft the dri ve l i ne modul e.
(4) I nstal l rotor on hub/beari ng.
(5) Careful l y l ower di sc brake cal i per and brake
shoes over rotor and onto cal i per adapter by revers-
i ng the removal procedure (Fi g. 92).
(6) I nstal l the di sc brake cal i per gui de pi n bol ts
(Fi g. 91). Ti ghten the gui de pi n bol ts to a torque of
22 Nm (192 i n. l bs.).
(7) Cl ean al l forei gn materi al off the threads of the
outer C/V joi nt stub shaft. I nstal l the washer and
hub nut (Fi g. 88) on the stub shaft of the outer C/V
joi nt.
(9) Set the park brake. This is required to keep
the driveshaft from rotating when tightening
and torquing the hub nut and driveshaft inner
joint to driveline module mounting nuts.
(11) Ti ghten the dri veshaft i nner joi nt to dri ve l i ne
modul e output shaft mounti ng bol ts (Fi g. 89) to a
(12) Ti ghten the outer C/V joi nt hub nut (Fi g. 88)
(13) I nstal l the spri ng washer (Fi g. 87) on the stub
shaft of the outer C/V joi nt.
(14) I nstal l the nut retai ner and cotter pi n (Fi g.
86) on the stub shaft of the outer C/V joi nt.
(15) I nstal l the wheel speed sensor on the hub/
beari ng and adapter. I nstal l the wheel speed sensor
attachi ng bol t (Fi g. 90). Ti ghten the wheel speed sen-
sor attachi ng bol t to a torque of 12 Nm (105 i n. l bs).
(19) Road test vehi cl e to ensure proper operati on
of the brake system.
MASTER CYLINDER
CAUTION: Different types of master cylinders are
used on this vehicle. Vehicles equipped with trac-
tion control use a center port master cylinder. Vehi-
cles not equipped with traction control use a
compensating port master cylinder. Be sure to ver-
ify if the vehicle is equipped with traction control
and that the correct replacement master cylinder is
used. Also, vehicles that are equipped with four
wheel disc brakes have a master with a different
size piston bore than the other master cylinders. If
a new master cylinder is being installed, be sure
the correct master cylinder is used for the type of
brake system the vehicle is equipped with.
REMOVE
CAUTION: Vacuum in the power brake booster
must be pumped down (removed) before removing
master cylinder from power brake booster. This is
necessary to prevent the power brake booster from
sucking in any contamination as the master cylin-
der is removed. This can be done simply by pump-
ing the brake pedal, with the vehicles engine not
running, until a firm feeling brake pedal is achieved.
(1) Wi th engi ne not runni ng, pump the brake
pedal unti l a fi rm pedal i s achi eved (4-5 strokes).
filler tube from the brake fluid reservoir, the filler
tube, brake fluid reservoir and master cylinder must
be thoroughly cleaned. This must be done to pre-
vent dirt particles from falling into the brake fluid
reservoir and entering the brakes hydraulic system.
(2) Thoroughl y cl ean al l surfaces of the fi l l er neck,
brake fl ui d reservoi r, and master cyl i nder. Use onl y a
sol vent such as Mopar Brake Parts Cl eaner or an
equi val ent.
(3) Remove master cyl i nder fi l l er tube from brake
fl ui d reservoi r by pushi ng down and rotati ng (Fi g.
97). Then remove the cap from the removed fi l l er
tube and i nstal l i t on the master cyl i nder reservoi r.
(4) Remove vehi cl e wi ri ng harness connector, from
the brake fl ui d l evel sensor, i n master cyl i nder brake
fl ui d reservoi r (Fi g. 98).
(5) Di sconnect the pri mary and secondary brake
tubes from the master cyl i nder housi ng (Fi g. 99).
I nstal l seal i ng pl ugs i n the open brake tube outl ets
on master cyl i nder assembl y.
5 - 44 BRAKES NS
from the power brake vacuum booster, the master
cylinder and vacuum booster must be thoroughly
cleaned. This must be done to prevent dirt particles
from falling into the power brake vacuum booster.
(6) Cl ean the area where the master cyl i nder
assembl y attaches to the power brake booster. Use
onl y a sol vent such as Mopar Brake Parts Cl eaner or
an equi val ent.
(7) Remove the 2 nuts attachi ng the master cyl i n-
der assembl y to the brake vacuum booster (Fi g. 100).
(8) Sl i de master cyl i nder assembl y strai ght out of
the power brake vacuum booster.
CAUTION: The master cylinder is used to create
the seal for holding vacuum in the power brake vac-
uum booster. The vacuum seal/boot on the master
cylinder MUST be replaced whenever the master
cylinder is removed from the power brake vacuum
booster.
(9) Remove the vacuum seal l ocated on the mount-
i ng fl ange of the master cyl i nder. The vacuum seal i s
removed from the master cyl i nder by carefully pul l -
i ng i t away from the master cyl i nder. Do not
attempt to pry the seal off the master cylinder
by inserting a sharp tool between seal and mas-
ter cylinder casting.
BLEEDING MASTER CYLINDER
CAUTION: When clamping master cylinder in vise,
only clamp master cylinder by its mounting flange,
do not clamp on primary piston, seal or body of
master cylinder.
(1) Cl amp the master cyl i nder i n a vi se usi ng onl y
the mounti ng fl ange (Fi g. 101).
Fig. 97 Master Cylinder Filler Tube Removal
Fig. 98 Electrical Connector At Fluid Level Sensor
Fig. 99 Primary/Secondary Brake Tubes At Master
Cylinder
Fig. 100 Master Cylinder Mounting To Vacuum
Booster
NS BRAKES 5 - 45
NOTE: Two different size bleeding tubes are used
depending on which type of master cylinder the
vehicle is equipped with. Vehicles equipped with
traction control use a center port master cylinder
with a larger diameter brake tube. Vehicles not
equipped with traction control use a compensating
port master cylinder using a standard 3/16 inch
diameter brake tube. Be sure the correct size bleed-
ing tubes are used when bleeding the master cylin-
der.
(2) I nstal l the Bl eedi ng Tubes, Speci al Tool 6920
for a non tracti on control master cyl i nder or Speci al
Tool 8129 for a tracti on control master cyl i nder on
the master cyl i nder (Fi g. 102). Posi ti on bl eedi ng
tubes so the outl ets of bl eedi ng tubes wi l l be bel ow
surface of brake fl ui d when reservoi r i s fi l l ed to i ts
proper l evel .
(3) Fi l l brake fl ui d reservoi r wi th brake fl ui d con-
formi ng to DOT 3 speci fi cati ons such as Mopar or an
Equi val ent.
(4) Usi ng a wooden dowel , (Fi g. 102) depress push
rod sl owl y, and then al l ow pi stons to return to
rel eased posi ti on. Repeat several ti mes unti l al l ai r
bubbl es are expel l ed from master cyl i nder.
(5) Remove bl eedi ng tubes from master cyl i nder
outl et ports, and then pl ug outl et ports and i nstal l
fi l l cap on reservoi r.
(6) Remove master cyl i nder from vi se.
NOTE: Note: It is not necessary to bleed the ABS
hydraulic control unit (HCU) after replacing the
master cylinder. But, the base brake hydraulic sys-
tem must be bled to ensure no air is entered the
hydraulic system when the master cylinder was
removed.
INSTALL
CAUTION: When replacing the master cylinder on
a vehicle, a NEW vacuum seal MUST be installed on
the master cylinder. Use only procedure detailed
below for installing the vacuum seal onto the mas-
ter cylinder.
(1) I nstal l a NEWvacuum seal on master cyl i nder
maki ng sure seal si ts squarel y i n groove of master
cyl i nder casti ng (Fi g. 103).
(2) Posi ti on master cyl i nder on studs of power
brake uni t, al i gni ng push rod on power brake vac-
uum booster wi th master cyl i nder push rod.
(3) I nstal l the 2 master cyl i nder to power brake
uni t mounti ng nuts. Then ti ghten both mounti ng
Fig. 101 Master Cylinder Correctly Mounted In Vise
Fig. 102 Bleeding Tubes Installed On Master
Cylinder
Fig. 103 Vacuum Seal Installed On Master Cylinder
5 - 46 BRAKES NS
CAUTION: When installing the primary and second-
ary brake tubes on master cylinder, be sure brake
tubes do not contact any other components within
the vehicle and that there is slack in the flexible
sections of the tubes. This is required due to the
movement between the ABS hydraulic control mod-
ule (HCU) and the master cylinder, when the vehicle
is in motion.
(4) Connect the pri mary and secondary brake
tubes to master cyl i nder pri mary and secondary
ports (Fi g. 99). Brake tubes must be hel d securel y
when ti ghtened to control ori entati on of fl ex secti on.
Then ful l y ti ghten the tube nuts to a torque of 17
Nm (145 i n. l bs.).
(5) I nstal l the vehi cl e wi ri ng harness connector, on
the brake fl ui d l evel sensor i n the master cyl i nder
brake fl ui d reservoi r (Fi g. 98).
(6) I nstal l fi l l er tube i nto the master cyl i nder fl ui d
reservoi r (Fi g. 97).
VACUUM BOOSTER 2. 4 LITER ENGINE
REMOVE
CAUTION: Reserve vacuum in the vacuum booster
master cylinder from vacuum booster. This is nec-
essary to prevent the vacuum booster from sucking
in any contamination as the master cylinder is
removed. This can be done simply by pumping the
brake pedal, with the vehicles engine not running,
until a firm feeling brake pedal is achieved.
(1) Wi th engi ne not runni ng, pump brake pedal
unti l a fi rm pedal i s achi eved (4-5 strokes).
(2) Remove both battery cabl es from battery.
(3) Remove the battery thermal guard and the bat-
tery from the battery tray.
(4) Remove the ai r i nl et resonator and hoses as an
assembl y from the throttl e body and ai r cl eaner
housi ng (Fi g. 104)
(5) I f vehi cl e i s equi pped wi th speed control ,
unpl ug wi ri ng harness connector from the speed con-
trol servo. Then di sconnect vacuum l i nes from the
speed control servo and vacuum reservoi r on battery
tray.
(6) Remove bol t attachi ng the speed control servo
bracket to the battery tray. Sl i de the bracket forward
to unhook i t from the battery tray and remove.
(7) Remove the 2 bol ts and the nut (Fi g. 105)
attachi ng the battery tray to the body.
(8) Remove wi ri ng harness connector from brake
fl ui d l evel sensor i n master cyl i nder fl ui d reservoi r
(Fi g. 106).
an equi val ent.
(10) Remove cl i p attachi ng drai n hose for wi per
modul e to brake tube at master cyl i nder. Remove
Fig. 104 Air Inlet Resonator
Fig. 105 Battery Tray Mounting Locations
Fig. 106 Fluid Level Sensor Electrical Connection
NS BRAKES 5 - 47
drai n hose (Fi g. 107) from wi per modul e. Remove the
2 nuts attachi ng the master cyl i nder to the vacuum
booster (Fi g. 107).
NOTE: It is not necessary to remove the brake
tubes from the master cylinder when removing the
master cylinder from the vacuum booster.
(11) Remove the master cyl i nder and brake tubes
as an assembl y from the vacuum booster. When mas-
ter cyl i nder i s removed, l ay i t out of the way on top
of the l eft motor mount
(12) Di sconnect vacuum hose from check val ve
l ocated on vacuum booster. DO NOT REMOVE
CHECK VALVE FROM POWER BRAKE
BOOSTER.
(13) Locate the vacuum booster i nput rod to brake
pedal attachment under i nstrument panel . Posi ti on a
smal l screwdri ver between the center tang on the
vacuum booster i nput rod to brake pedal pi n retai n-
i ng cl i p (Fi g. 108).
(14) Rotate screwdri ver enough to al l ow retai ni ng
cl i p center tang to pass over end of brake pedal pi n.
Then pul l retai ni ng cl i p off brake pedal pi n. Discard
retaining clip. It is not to be reused. Replace
only with a new retaining clip when assembled.
(15) Remove the 4 nuts attachi ng the vacuum
booster to the dash panel . Nuts are accessi bl e from
under dash panel i n area of the steeri ng col umn and
pedal bracket assembl y.
(16) From outsi de the vehi cl e, sl i de vacuum
booster forward unti l i ts mounti ng studs cl ear dash
panel . Then ti l t the booster up and toward the center
of vehi cl e to remove.
CAUTION: Do not attempt to disassemble the vac-
uum booster it is to be serviced ONLY as a com-
plete assembly.
INSTALL
CAUTION: When installing the vacuum booster in
the vehicle be sure the heater hoses do not become
trapped between the booster and the dash panel of
the vehicle.
(1) Posi ti on vacuum booster onto dash panel usi ng
the reverse procedure for i ts removal .
(2) I nstal l the 4 mounti ng nuts for the vacuum
booster. Ti ghten the 4 mounti ng nuts to a torque of
29 Nm (250 i n. l bs.).
(3) Usi ng l ubri pl ate, or an equi val ent, coat the sur-
face of the brake pedal pi n where i t contacts the vac-
uum booster i nput rod.
CAUTION: When installing the brake pedal pin on
the vacuum booster input rod, do not re-use the old
retaining clip.
(4) Connect the vacuum booster i nput rod on the
brake pedal pi n and i nstal l a NEW retai ni ng cl i p
(Fi g. 109).
(5) Connect the vacuum hose on the check val ve i n
the vacuum booster.
the seal for holding vacuum in the vacuum booster.
The vacuum seal on the master cylinder MUST be
replaced with a NEW seal whenever the master cyl-
inder is removed from the vacuum booster.
CAUTION: When removing the vacuum seal from
the master cylinder do not use a sharp tool.
(6) Usi ng a soft tool such as a tri m sti ck, remove
the vacuum seal from the master cyl i nder mounti ng
fl ange.
Fig. 107 Master Cylinder Attachment To Vacuum
Booster
Fig. 108 Input Rod Retaining Pin
5 - 48 BRAKES NS
(7) I nstal l a NEWvacuum seal on mounti ng fl ange
of master cyl i nder (Fi g. 110).
(8) Posi ti on master cyl i nder on studs of vacuum
booster al i gni ng push rod on vacuum booster wi th
master cyl i nder pi ston.
(9) I nstal l the 2 nuts (Fi g. 107) mounti ng the mas-
ter cyl i nder to the vacuum booster. Ti ghten the
mounti ng nuts to a torque of 25 Nm (225 i n. l bs.).
(10) I nstal l the wi per modul e drai n hose (Fi g. 107)
on the wi per modul e. I nstal l the ti e strap attachi ng
the wi per modul e drai n hose to the brake tube at the
master cyl i nder. Tie strap should be loosely tight-
ened so as not to collapse the wiper module
drain hose.
(11) I nstal l the wi ri ng harness connector on the
brake fl ui d l evel sensor i n the master cyl i nder fl ui d
(12) I nstal l the battery tray i n the vehi cl e. I nstal l
the 2 bol ts and the nut (Fi g. 105) attachi ng the bat-
tery tray. Ti ghten the 2 bol ts and the nut to a torque
of 14 Nm (125 i n l bs.).
i nstal l the speed control servo and bracket on the
battery tray. I nstal l and securel y ti ghten bol t attach-
i ng bracket to battery tray.
i nstal l the wi ri ng harness connector on the speed
control servo. Then connect the vacuum l i nes onto
the speed control servo and vacuum reservoi r on bat-
tery tray.
(15) I nstal l the ai r i nl et resonator and hoses as an
assembl y on the throttl e body and ai r cl eaner hous-
i ng (Fi g. 104). Securel y ti ghten the hose cl amp at the
ai r cl eaner housi ng and throttl e body.
(16) I nstal l the battery and the battery thermal
guard.
(17) I nstal l the battery cabl es on the battery.
(18) Check the operati on of the stop l amp swi tch
and adjust i f necessary.
VACUUM BOOSTER 3. 0 LITER ENGINE
REMOVE
CAUTION: Stored vacuum in the vacuum booster
master cylinder from power brake booster. This is
necessary to prevent the power brake booster from
sucking in any contamination as the master cylin-
der is removed. This can be done simply by pump-
ing the brake pedal, with the vehicles engine not
running, until a firm feeling brake pedal is achieved.
tray.
attachi ng the battery tray to the body of the vehi cl e.
(Fi g. 113).
an equi val ent.
Fig. 109 Retaining Clip Installed On Brake Pedal Pin
NS BRAKES 5 - 49
(10) Remove cl i p attachi ng drai n hose to brake
tube at master cyl i nder. Remove drai n hose (Fi g. 114)
from wi per modul e. Remove the 2 nuts attachi ng the
master cyl i nder assembl y to the power brake vacuum
master cylinder from the power brake vacuum
booster.
(11) Remove the master cyl i nder and the brake
tubes as an assembl y from power brake vacuum
booster. When master cyl i nder i s removed, l ay i t out
of the way on top of the l eft motor mount
l ocated on power brake vacuum booster. DO NOT
REMOVE CHECK VALVE FROM POWER
BRAKE BOOSTER.
(13) Locate the power brake vacuum booster i nput
rod to brake pedal attachment under i nstrument
panel . Posi ti on a smal l screwdri ver between the cen-
ter tang on the power brake booster i nput rod to
brake pedal pi n retai ni ng cl i p (Fi g. 115).
only with a new retaining clip when assembled.
(15) Remove the 4 nuts attachi ng the vacuum
booster to the dash panel . Nuts are accessi bl e from
under dash panel i n area of the steeri ng col umn and
pedal bracket assembl y.
(16) From outsi de the vehi cl e, sl i de power brake
vacuum booster forward unti l i ts mounti ng studs
Fig. 113 Electrical Connection To Fluid Level Sensor
Fig. 114 Master Cylinder Attachment To Power
Brake Vacuum Booster
5 - 50 BRAKES NS
cl ear dash panel . Then ti l t the booster up and toward
the center of vehi cl e to remove.
CAUTION: Do not attempt to disassemble the
power brake vacuum booster it is to be serviced
ONLY as a complete assembly.
INSTALL
CAUTION: When installing the power brake vacuum
booster in the vehicle be sure the heater hoses do
not become trapped between the booster and the
dash panel of the vehicle.
(1) Posi ti on power brake booster onto dash panel
usi ng the reverse procedure for i ts removal .
(2) I nstal l the 4 power brake vacuum booster
mounti ng nuts. Ti ghten the 4 mounti ng nuts to a
torque of 29 Nm (250 i n. l bs.).
face of the brake pedal pi n where i t contacts the
brake vacuum booster i nput rod.
the power brake vacuum booster input rod, do not
re-use the old retaining clip.
(4) Connect power brake vacuum booster i nput rod
on the brake pedal pi n and i nstal l a NEW retai ni ng
cl i p (Fi g. 116).
the seal for holding vacuum in the power brake vac-
uum booster. The vacuum seal on the master cylin-
der MUST be replaced with a NEW seal whenever
the master cylinder is removed from the power
brake vacuum booster.
fl ange.
of master cyl i nder assembl y (Fi g. 117).
(8) Posi ti on master cyl i nder on studs of power
brake booster, al i gni ng push rod on power brake vac-
uum booster wi th master cyl i nder push rod.
(9) I nstal l the 2 master cyl i nder to power brake
uni t mounti ng nuts (Fi g. 114). Ti ghten both mount-
i ng nuts to a torque of 25 Nm (225 i n. l bs.).
the wi per modul e drai n hose to brake tube at the
drain hose.
Fig. 115 Booster Input Rod Retaining Pin Fig. 116 Retaining Pin Installed On Brake Pedal Pin
NS BRAKES 5 - 51
(12) I nstal l the battery tray i n the vehi cl e. I nstal l
the 2 bol ts and the nut (Fi g. 112) attachi ng the bat-
tery tray to the vehi cl e. Ti ghten the 2 bol ts and the
nut to a torque of 14 Nm (125 i n l bs.).
tery tray.
i ng (Fi g. 111). Securel y ti ghten the hose cl amp at the
ai r cl eaner housi ng and throttl e body.
guard.
VACUUM BOOSTER 3. 3/3. 8 LITER ENGINE
REMOVE
CAUTION: Reserve vacuum in the vacuum booster
master cylinder from vacuum booster. This is nec-
essary to prevent the vacuum booster from sucking
in any contamination as the master cylinder is
removed. This can be done simply by pumping the
brake pedal, with the vehicles engine not running,
until a firm feeling brake pedal is achieved.
tray.
attachi ng the battery tray to the body of the vehi cl e.
(8) Remove the wi ri ng harness connector (Fi g. 120)
from the EGR val ve transducer.
(9) Remove wi ri ng harness connectors from throt-
tl e posi ti on sensor and AI S motor on throttl e body
(Fi g. 121).
(10) Remove the 2 bol ts (Fi g. 122) attachi ng the
throttl e body to the i ntake mani fol d and the cl i p (Fi g.
122) attachi ng the wi ri ng harness to the throttl e
cabl e bracket. Then remove the throttl e body and
throttl e cabl e bracket as an assembl y from the i ntake
mani fol d.
(Fi g. 123).
5 - 52 BRAKES NS
an equi val ent.
(13) Remove cl i p, attachi ng drai n hose for wi per
modul e to brake tube at master cyl i nder. Remove
drai n hose (Fi g. 124) from wi per modul e. Remove the
2 nuts, attachi ng the master cyl i nder to the vacuum
master cylinder from the vacuum booster.
(14) Remove master cyl i nder and brake tubes as
an assembl y from the vacuum booster. When master
cyl i nder i s removed, l ay i t out of the way on top of
the l eft motor mount
Fig. 120 Electrical Connector At EGR Transducer
Fig. 121 Electrical And Vacuum Connections To
Throttle Body
Fig. 122 Throttle Body Attachment To Intake
Manifold
Fig. 124 Master Cylinder Attachment To Vacuum
Booster
NS BRAKES 5 - 53
(15) Remove the EGR Val ve and the vacuum
transducer (Fi g. 125) as an assembl y from the i ntake
mani fol d.
l ocated on vacuum booster. DO NOT REMOVE
CHECK VALVE FROM POWER BRAKE
BOOSTER.
(17) Locate the vacuum booster i nput rod to brake
pedal connecti on under the i nstrument panel . Posi -
ti on a smal l screwdri ver between the center tang on
the power brake booster i nput rod to brake pedal pi n
retai ni ng cl i p (Fi g. 126).
only with a new retaining clip when assem-
bling.
(19) Remove the 4 nuts attachi ng the power brake
vacuum booster to the dash panel . Nuts are accessi -
bl e from under dash panel i n area of the steeri ng col -
umn and pedal bracket assembl y.
(20) From outsi de the vehi cl e, sl i de power brake
vacuum booster forward unti l i ts mounti ng studs
cl ear dash panel . Then ti l t the booster up and toward
the center of vehi cl e to remove.
CAUTION: Do not attempt to disassemble the
power brake vacuum booster it is to be serviced
ONLY as a complete assembly.
INSTALL
CAUTION: When installing the power brake vacuum
booster in the vehicle be sure the heater hoses do
not become trapped between the booster and the
dash panel of the vehicle.
(1) Posi ti on vacuum booster on dash panel usi ng
the reverse procedure of i ts removal .
(2) I nstal l the 4 nuts mounti ng the vacuum
booster to the dash panel . Ti ghten the 4 mounti ng
face of the brake pedal pi n where i t contacts the vac-
uum booster i nput rod.
the power brake vacuum booster input rod, do not
re-use the old retaining clip.
(4) I nstal l vacuum booster i nput rod on brake
pedal pi n and i nstal l a NEWretai ni ng cl i p (Fi g. 127).
(6) I nstal l EGR Val ve and vacuum transducer (Fi g.
125) on the i ntake mani fol d. I nstal l and ti ghten the 2
EGR val ve mounti ng bol ts to a torque of 22 Nm (200
i n. l bs.).
Fig. 125 EGR Valve Attachment To Intake Manifold
Fig. 126 Vacuum Booster Input Rod Retaining Pin
Fig. 127 Retaining Pin Installed On Brake Pedal Pin
5 - 54 BRAKES NS
the seal for holding vacuum in the vacuum booster.
The vacuum seal on the master cylinder MUST be
replaced with a NEW seal whenever the master cyl-
inder is removed from the vacuum booster.
fl ange.
of the master cyl i nder (Fi g. 128).
(9) Posi ti on master cyl i nder on studs of vacuum
booster, al i gni ng push rod on vacuum booster wi th
master cyl i nder pi ston.
(10) I nstal l the 2 nuts mounti ng the master cyl i n-
der to the vacuum booster (Fi g. 124). Ti ghten both
mounti ng nuts to a torque of 25 Nm (225 i n. l bs.).
the wi per modul e drai n hose to brake tube at the
drain hose.
(13) I nstal l the throttl e body and throttl e cabl e
bracket on the i ntake mani fol d. I nstal l the 2 bol ts
(Fi g. 122) attachi ng the throttl e body to the i ntake
mani fol d and ti ghten to a torque of 25 Nm (225 i n.
l bs.) I nstal l cl i p (Fi g. 122) attachi ng the wi ri ng har-
ness to the throttl e cabl e bracket.
(14) I nstal l the wi ri ng harness connectors on the
throttl e posi ti on sensor and the AI S motor on throttl e
body (Fi g. 121).
(15) I nstal l the wi ri ng harness connector (Fi g. 120)
on the EGR val ve transducer.
(16) I nstal l the battery tray. I nstal l the 2 bol ts and
the nut (Fi g. 119) attachi ng the battery tray to the
vehi cl e. Ti ghten the 2 bol ts and the nut to a torque of
14 Nm (125 i n l bs.).
tery tray.
i ng (Fi g. 118). Securel y ti ghten hose cl amp at ai r
cl eaner housi ng and throttl e body.
guard.
JUNCTION BLOCK
REMOVE
(1) Usi ng a brake pedal depressor, move and l ock
the brake pedal to a posi ti on past i ts fi rst 1 i nch of
travel . Thi s wi l l prevent brake fl ui d from drai ni ng
out of the master cyl i nder when the brake tubes are
removed from the juncti on bl ock.
nance Group of thi s servi ce manual .
CAUTION: Before removing the brake tubes from
the junction block, the junction block and the brake
tubes must be thoroughly cleaned. This is required
to prevent contamination from entering the brake
hudraulic system.
(3) Remove the 6 chassi s brake tubes (Fi g. 129)
from the juncti on bl ock.
(4) Remove the bol t (Fi g. 130) attachi ng the junc-
ti on bl ock mounti ng braket to the front suspensi on
cradl e.
INSTALL
(1) I nstal l the juncti on bl ock and mounti ng bracket
(Fi g. 130) on the front suspensi on cradl e. I nstal l the
i n. l bs.).
(2) I nstal l the 6 chassi s brake tubes (Fi g. 131) i nto
the i nl et and outl et ports of the juncti on bl ock.
NS BRAKES 5 - 55
Ti ghten al l 6 tube nuts to a torque of 16 Nm (145 i n.
l bs.).
(3) Bl eed the brake system thoroughl y to ensure
that al l ai r has been expel l ed from the hydraul i c sys-
tem. See Bl eedi ng Brake System i n the Servi ce
Adjustments secti on i n thi s group of the servi ce man-
ual for the proper bl eedi ng procedure.
(4) Lower the vehi cl e.
(5) Road test the vehi cl e to veri fy proper operati on
of the vehi cl es brake system.
PROPORTIONING VALVE (W/ABS BRAKES)
The actual proporti oni ng val ves of the proporti on-
i ng val ve assembl y are not servi ceabl e or repl aceabl e.
I f a proporti oni ng val ve of the proporti oni ng val ve
assembl y i s not functi oni ng properl y, the fi xed pro-
porti oni ng val ve must be repl aced as an assembl y.
REMOVE
removed from the proporti oni ng val ve.
the proportioning valve, the proportioning valve and
the brake tubes must be thoroughly cleaned. This is
required to prevent contamination from entering the
proportioning valve or the brake tubes.
(3) Remove the 4 chassi s brake l i nes from the i nl et
and outl et ports of the proporti oni ng val ve (Fi g. 132).
(4) Remove the bol ts (Fi g. 133) attachi ng the pro-
porti oni ng val ve bracket to the frame rai l of the vehi -
cl e. Remove the fi xed proporti oni ng val ve assembl y
from the vehi cl e.
Fig. 129 Junction Block Brake Tubes
Fig. 130 Junction Block Mounting
Fig. 131 Brake Tube Connections To Junction Block
Fig. 132 Chassis Brake Tubes At Proportioning
Valve
5 - 56 BRAKES NS
INSTALL
CAUTION: When mounting the original or a
replacement proportioning valve on the frame rail of
the vehicle install the mounting bolts in only the
two forward holes of the mounting bracket (Fig.
133).
(1) I nstal l proporti oni ng val ve assembl y on the
frame rai l of the vehi cl e. I nstal l the proporti oni ng
val ve assembl y attachi ng bol ts (Fi g. 133). Ti ghten the
attachi ng bol ts to a torque of 14 Nm (125 i n. l bs.).
(2) I nstal l the 4 chassi s brake l i nes (Fi g. 132) i nto
the i nl et and outl et ports of the proporti oni ng val ve
assembl y. Ti ghten al l 4 l i ne nuts to a torque of 16
Nm (142 i n. l bs.).
(3) Bl eed the brake system thoroughl y enough to
ensure that al l ai r has been expel l ed from the
hydraul i c system. See Bl eedi ng Brake System i n the
Servi ce Adjustments secti on i n thi s group of the ser-
vi ce manual for the proper bl eedi ng procedure.
(4) Lower the vehi cl e to the ground.
PROPORTIONING VALVE (W/O ABS BRAKES)
The components of the proporti oni ng val ve assem-
bl y are not servi ceabl e or repl aceabl e. I f a component
of the proporti oni ng val ve assembl y i s not functi on-
i ng properl y, the proporti oni ng val ve must be
repl aced as an assembl y.
REMOVE
removed from the proporti oni ng val ve.
the proportioning valve, the proportioning valve and
the brake tubes must be thoroughly cleaned. This is
required to prevent contamination from entering the
proportioning valve or the brake tubes.
(3) Remove the 4 chassi s brake tubes from the
i nl et and outl et ports of the proporti oni ng val ve (Fi g.
134).
proporti oni ng val ve to the proporti oni ng val ve
mounti ng bracket. Remove the proporti oni ng val ve
from the mounti ng bracket.
(5) Remove the hooked end of the proporti oni ng
val ve actuator (Fi g. 136) from the i sol ator bushi ng on
the l ever of the hei ght proporti oni ng val ve (Fi g. 136).
Fig. 133 Proportioning Valve Attachment To Vehicle
Fig. 134 Chassis Brake Tubes At Proportioning
Valve
Fig. 135 Proportioning Valve Mounting
NS BRAKES 5 - 57
INSTALL
(1) I nstal l the hooked end of the actuator on the
proporti oni ng val ve l ever (Fi g. 136). Be sure isola-
tor bushing on lever of proportioning valve
(Fig. 136) is fully seated in hook of actuator.
NOTE: When installing height sensing proportion-
ing valve on mounting bracket be sure proportion-
ing valve shield (Fig. 135) is installed between the
proportioning valve and the mounting bracket.
(2) I nstal l hei ght sensi ng proporti oni ng val ve on
mounti ng bracket. I nstal l the proporti oni ng val ve
attachi ng bol ts (Fi g. 135). Ti ghten the attachi ng bol ts
to a torque of 23 Nm (200 i n. l bs.).
(3) I nstal l the 4 chassi s brake l i nes (Fi g. 134) i nto
the i nl et and outl et ports of the proporti oni ng val ve.
Ti ghten al l 4 l i ne nuts to a torque of 16 Nm (142 i n.
l bs.).
(4) Adjust the proporti oni ng val ve actuator. See
Hei ght Sensi ng Proporti oni ng Val ve i n the Adjust-
ment Secti on i n thi s group of the servi ce manual for
the adjustment procedure.
(5) Bl eed the brake system thoroughl y to ensure
that al l ai r has been expel l ed from the hydraul i c sys-
tem. See Bl eedi ng Brake System i n the Servi ce
Adjustments secti on i n thi s group of the servi ce man-
ual for the proper bl eedi ng procedure.
(6) Lower the vehi cl e to the ground.
HYDRAULIC BRAKE TUBES AND HOSES
CAUTION: When installing brake chassis lines or
flex hoses on the vehicle, the correct fasteners
must be used to attach the routing clips or hoses to
the front suspension cradle. The fasteners used to
attach components to the front suspension cradle
have an anticorrosion coating due to the suspen-
sion cradle being made of aluminum. Only Mopar
replacement fasteners with the required anti-corro-
sion coating are to be used if a replacement fas-
tener is required when installing a brake chassis
line or flex hose.
Onl y doubl e wal l 4.75mm (3/16 i n.) steel tubi ng
wi th Al -ri ch/ZW-AC al l oy coati ng and the correct tube
nuts are to be used for repl acement of a hydraul i c
brake tube.
NOTE: On vehicles equipped with traction control,
the primary and secondary hydraulic tubes between
the master cylinder and the hydraulic control unit
are 6 mm (15/64 in.). These tubes are also coated
with the Al-rich/ZW-AC alloy and must be replaced
with tubes having the same anti-corrosion coating.
Be sure that the correct tube nuts are used for the
replacement of these hydraulic brake tubes.
Care shoul d be taken when repl aci ng brake tubi ng,
to be sure the proper bendi ng and fl ari ng tool s and
procedures are used, to avoi d ki nki ng. Do not route
the tubes agai nst sharp edges, movi ng components or
i nto hot areas. Al l tubes shoul d be properl y attached
wi th recommended retai ni ng cl i ps.
I f the pri mary or secondary brake tube from the
master cyl i nder to the ABS Hydraul i c Control Uni t
(HCU) or the brake tubes from the HCU to the pro-
porti oi ng val ve requi re repl acement, only the ori gi -
nal factory brake l i ne contai ni ng the fl exi bl e secti on
can be used as the repl acement part. Thi s i s requi red
due to cradl e movement whi l e the vehi cl e i s i n
moti on.
PARK BRAKE PEDAL MECHANISM
REMOVE
(1) Di sconnect negati ve (ground) cabl e from the
battery and i sol ate cabl e from battery termi nal .
(2) Remove si l l scuff pl ate from l eft door si l l .
(3) Remove the l eft si de ki ck panel .
(4) Remove the steeri ng col umn cover from the
l ower i nstrument panel .
(5) Remove the rei nforcement from the l ower
i nstrument panel .
(6) Lock out front park brake cabl e usi ng the fol -
l owi ng procedure. Grasp the exposed secti on of the
front park brake cabl e and pul l rearward on i t. Whi l e
hol di ng the park brake i n thi s posi ti on, i nstal l a pai r
of l ocki ng pl i ers on the front park brake cabl e just
rearward of the second body outri gger bracket (Fi g.
137).
(7) Remove the front park brake cabl e from the
park brake cabl e equal i zer.
Fig. 136 Actuator Attachment To Proportioning
Valve
5 - 58 BRAKES NS
(8) Remove tensi on from front park brake cabl e.
Tensi on i s removed by rel easi ng the l ocki ng pl i ers
from the front park brake cabl e.
(9) Remove the 3 bol ts mounti ng the wi ri ng junc-
ti on bl ock to the i nstrument panel .
NOTE: When removing the lower mounting bolt,
push the park brake pedal down 5 clicks to access
the lower mounting bolt.
(10) Remove the l ower bol t mounti ng the park
brake pedal to the body.
(11) Remove the forward bol t mounti ng the park
(12) Remove the upper bol t mounti ng the park
(13) Di sconnect the el ectri cal connector for the
brake l i ght swi tch (Fi g. 138).
(14) Pul l downward on front park brake cabl e
whi l e rotati ng park brake pedal mechani sm out from
behi nd juncti on bl ock.
(15) Remove park brake pedal rel ease cabl e (Fi g.
138) from park brake mechani sm.
(16) Remove the ground swi tch for the red brake
warni ng l amp from the park brake pedal mechani sm.
(17) Remove front park brake cabl e button from
park brake pedal mechani sm. Tap end housi ng of
front park brake cabl e out of park brake pedal mech-
ani sm (Fi g. 138).
INSTALL
(1) I nstal l the ground swi tch for the red brake
warni ng l amp on the park brake pedal mechani sm
(2) I nstal l park brake cabl e end housi ng (Fi g. 138)
i nto park brake pedal mechani sm.
(3) I nstal l cabl e retai ner (Fi g. 138) onto the park
brake cabl e strand and then i nstal l retai ner i nto
pedal bracket.
(4) I nstal l cabl e strand button i nto the cl evi s on
(5) I nstal l wi ri ng harness connector on red brake
warni ng l amp ground swi tch.
(6) I nstal l the park brake rel ease cabl e on the
rel ease mechani sm of the park brake pedal .
(7) Posi ti on the park brake pedal mechani sm i nto
i ts i nstal l ed posi ti on on the body of the vehi cl e.
(8) Remove the l ock-out pi n from the park brake
pedal rel ease mechani sm.
(9) Loosel y i nstal l the top bol t (Fi g. 138) mounti ng
the park brake pedal mechani sm to the body.
(10) Loosel y i nstal l the forward bol t (Fi g. 138)
mounti ng the park brake pedal mechani sm to the
body.
(11) Loosel y i nstal l the l ower bol t (Fi g. 138)
mounti ng the park brake pedal mechani sm to the
body.
(12) Ti ghten pedal mechani sm attachi ng bol ts to
28 Nm (250 i n. l bs.).
(13) Veri fy that the park brake pedal i s i n the ful l y
rel eased (ful l up) posi ti on.
(15) I nstal l the front park brake cabl e on the park
brake cabl e equal i zer.
(17) Remove the l ock-out pi n (Fi g. 138) from the
automati c cabl e adjuster on the park brake pedal
mechani sm.
(18) I nstal l the el ectri cal juncti on bl ock on the
i nstrument panel .
(19) I nstal l the rei nforcement on the l ower i nstru-
ment panel .
(20) I nstal l the steeri ng col umn cover on the l ower
i nstrument panel .
(21) I nstal l the l eft si de ki ck panel .
(22) I nstal l the si l l scuff pl ate on the l ower si l l of
the l eft door.
Fig. 137 Locking Out Automatic Adjuster Fig. 138 Park Brake Pedal Mounting
NS BRAKES 5 - 59
(23) I nstal l the negati ve (ground) cabl e on the bat-
tery.
(24) Cycl e the park brake pedal one ti me. Thi s wi l l
seat the park brake cabl es and wi l l al l ow the auto-
mati c sel f adjuster to properl y tensi on the park brake
cabl es.
PARK BRAKE SHOES (WITH REAR DISC BRAKES)
On thi s vehi cl e, the park brake shoes are removed
from the di sc brake adapter wi th the di sc brake
adapter removed from the vehi cl e.
REMOVE
(1) Set the parki ng brake. The parking brake is
set to keep the hub/bearing and axle shaft from
rotating when loosening the hub nut.
(3) Remove the wheel /ti re.
(4) Remove the cotter pi n and nut retai ner (Fi g.
139) from the stub shaft of the outer C/V joi nt.
(5) Remove the spri ng washer (Fi g. 140) from the
(6) Remove the hub nut and washer (Fi g. 141)
from the stub shaft of the outer C/V joi nt.
(7) Rel ease the parki ng brake.
(8) Create sl ack i n the rear park brake cabl es by
l ocki ng the out the automati c adjuster as descri bed.
Grasp the exposed secti on of front park brake cabl e
and pul l downward on i t. Then i nstal l a pai r of l ock-
(9) Remove the di sc brake cal i per to adapter gui de
(10) Remove rear cal i per from adapter usi ng the
fol l owi ng procedure. Fi rst rotate rear of cal i per up
from the adapter. Then pul l the front of the cal i per
and the outboard brake shoe anti -rattl e cl i p out from
Fig. 139 Cotter Pin And Nut Retainer
Fig. 140 Spring Washer
Fig. 141 Hub Nut And Washer
5 - 60 BRAKES NS
145).
(12) Remove the rotor from the hub/beari ng.
(13) Remove the horseshoe cl i p (Fi g. 146) from the
retai ner on the end of the park brake cabl e.
(14) Remove the end of the park brake cabl e from
the actuator l ever on the adapter (Fi g. 146).
(15) Remove the end of the park brake cabl e from
the adapter. Park brake cabl e i s removed from
adapter usi ng a 1/2 wrench sl i pped over the park
brake cabl e retai ner as show i n (Fi g. 147) to com-
press the l ocki ng tabs on the park brake cabl e
retai ner.
(16) Remove the attachi ng bol t from the wheel
speed sensor (Fi g. 148). Then remove wheel speed
sensor from hub/beari ng and adapter.
(17) Remove the hub/beari ng to axl e mounti ng
bol ts (Fi g. 149).
(18) Remove the hub/beari ng from the axl e and the
stub shaft of the outer C/V joi nt (Fi g. 150).
(19) Remove the adapter from the rear axl e.
(20) Mount the adapter i n a vi se usi ng the anchor
boss for the park brake cabl e (Fi g. 151).
Fig. 146 Park Brake Cable Attachment To Actuator
Fig. 147 Park Brake Cable Removal From Adapter
NS BRAKES 5 - 61
(21) Remove the l ower return spri ng (Fi g. 152)
from the l eadi ng and trai l i ng park brake shoes.
(22) Remove the hol d down spri ng and pi n (Fi g.
153) from the l eadi ng park brake shoe.
Fig. 148 Speed Sensor Attaching Bolt
Fig. 149 Hub/Bearing Mounting Bolts
Fig. 150 Hub/Bearing Removal And Installation
Fig. 151 Adapter Mounted In Vise
Fig. 152 Lower Return Spring
Fig. 153 Leading Brake Shoe Hold Down Pin And
Spring
5 - 62 BRAKES NS
(23) Remove the adjuster (Fi g. 154) from the l ead-
i ng and trai l i ng park brake shoe.
(24) Remove the l eadi ng park brake shoe (Fi g.
155) from the adapter. Leadi ng brake shoe i s
removed by rotati ng the bottom of the brake shoe
i nward (Fi g. 155) unti l the top of the brake shoe can
be removed from the brake shoe anchor. Then remove
the upper return spri ngs (Fi g. 155) from the l eadi ng
brake shoe.
(25) Remove the upper return spri ngs (Fi g. 156)
from the trai l i ng park brake shoe.
(26) Remove the hol d down spri ng and pi n (Fi g.
157) from the trai l i ng park brake shoe.
(27) Remove the trai l i ng park brake shoe from the
adapter.
(28) Remove the park brake shoe actuator from
the adapter and i nspect for si gns of abnormal wear
and bi ndi ng at the pi vot poi nt.
INSTALL
(1) I nstal l the trai l i ng brake shoe on the adapter.
NOTE: When the hold down pin is installed, the
long part of the hold down pin is to be positioned
strait up and down. This will ensure that the hold
down pin is correctly engaged with the adapter.
(2) I nstal l the hol d down spri ng and pi n (Fi g. 157)
on the trai l i ng park brake shoe.
(3) I nstal l the upper return spri ngs (Fi g. 156) on
the trai l i ng park brake shoe.
(4) I nstal l the upper return spri ngs on the l eadi ng
park brake shoe (Fi g. 155). Then posi ti on the top of
the l eadi ng park brake shoe at the upper anchor and
rotate the bottom of the shoe outward unti l correctl y
i nstal l ed on the adapter.
(5) I nstal l the adjuster (Fi g. 154) between the
l eadi ng and trai l i ng park brake shoe.
Fig. 154 Brake Shoe Adjuster
Fig. 155 Primary Brake Shoe Remove/Install
Fig. 156 Upper Return Springs
Fig. 157 Trailing Brake Shoe Hold Down Pin And
Spring
NS BRAKES 5 - 63
NOTE: When the hold down pin is installed, the
long part of the hold down pin is to be positioned
strait up and down. This will ensure that the hold
down pin is correctly engaged with the adapter.
(6) I nstal l the hol d down spri ng and pi n (Fi g. 153)
on the l eadi ng park brake shoe.
(7) I nstal l the l ower return spri ng (Fi g. 152) on
the l eadi ng and trai l i ng park brake shoes. When
installing the hold down spring it is to be
installed behind the park brake shoes (Fig.
152).
(8) I nstal l the 4 mounti ng bol ts for the adapter
and hub/beari ng i nto the bol t hol es i n the axl e.
(9) Posi ti on the adapter on the 4 mounti ng bol ts
i nstal l ed i n the rear axl e (Fi g. 158).
(10) I nstal l the hub/beari ng on the stub shaft of
outer C/V joi nt and i nto the end of the axl e. (Fi g.
150).
(11) I n a progressi ve cri ss-cross pattern, ti ghten
the 4 hub/beari ng mounti ng bol ts unti l the hub/bear-
i ng i s squarel y seated agai nst the axl e. Then ti ghten
the hub/beari ng mounti ng bol ts to a torque of 129
Nm (95 ft. l bs.).
(12) I nstal l the wheel speed sensor on the hub/
beari ng and adapter. I nstal l the wheel speed sensor
attachi ng bol t (Fi g. 148). Ti ghten the wheel speed
sensor attachi ng bol t to a torque of 12 Nm (105 i n.
l bs).
(13) I nstal l the park brake cabl e i nto i ts mounti ng
hol e i n the adapter. Be sure all the locking tabs
on the park brake cable retainer are expanded
out to ensure the cable will not pull out of the
adapter.
(14) I nstal l the end of the park brake cabl e on the
park brake actuator l ever (Fi g. 146).
NOTE: The horseshoe clip must be installed and
installed properly when the park brake cable is
installed in the adapter. The purpose of the horse-
shoe clip is to prevent park brake cable retainer
from moving in the adapter. If horseshoe clip is not
installed the park brake cable retainer will rattle in
the adapter.
(15) I nstal l a NEW horseshoe cl i p on the park
brake cabl e retai ner (Fi g. 146). The horseshoe cl i p i s
i nstal l ed between the retai ner for the park brake
cabl e and the adapter. Horseshoe cl i p must be
i nstal l ed wi th the curved end of the cl i p poi nti ng
strai ght up and the edge of the curved end faci ng
toward the rear of the vehi cl e (Fi g. 146).
(16) Remove the l ocki ng pl i ers (Fi g. 142) from the
front park brake cabl e.
(17) Adjust the park brake drum-i n-hat brake
shoes. See Park Brake Shoe Adjustment i n the
adjustment secti on i n thi s group of the servi ce man-
ual for the proper park brake shoe adjustment proce-
dure.
(18) I nstal l the rotor on the hub/beari ng.
rotor and onto the adapter usi ng the reverse proce-
dure for removal (Fi g. 144).
(20) I nstal l the cal i per gui de pi n bol ts (Fi g. 143).
Ti ghten the gui de pi n bol ts to a torque of 22 Nm
(192 i n. l bs.).
(21) Cl ean al l forei gn materi al off the threads of
the outer C/V joi nt stub shaft. I nstal l the washer and
hub nut (Fi g. 141) on the stub shaft of the outer C/V
joi nt.
(22) Set the parki ng brake.
(23) Ti ghten the hub nut to a torque of 244 Nm
(180 ft. l bs.).
(24) I nstal l the spri ng washer (Fi g. 140) on the
(25) I nstal l the nut retai ner and cotter pi n (Fi g.
139) on the stub shaft of the outer C/V joi nt.
(29) Fully apply and release the park brake
pedal one time. This will seat and correctly
adjust the park brake cables.
Fig. 158 Adapter Installed On Mounting Bolts
5 - 64 BRAKES NS
(30) Road test the vehi cl e and make several stops
to wear off any forei gn materi al on the brakes and to
FRONT PARK BRAKE CABLE
REMOVE
(2) Manual l y l ockout the automati c sel f adjusti ng
mechani sm of the park brake pedal assembl y. Refer
to Manual Lockout Of Auto Adjuster Mechani sm i n
thi s secti on of the servi ce manual for the requi red
procedure.
(3) Remove the i ntermedi ate and l eft rear park
159).
(4) Remove the front park cabl e housi ng retai ner
from body outri gger bracket (Fi g. 160). Cabl e i s
removabl e by sl i di ng a 14 mm box wrench over cabl e
retai ner and compressi ng the three retai ni ng fi ngers.
Al ternate method i s to use an ai rcraft type hose
cl amp and screwdri ver.
(6) Remove the l eft front door si l l mol di ng.
(7) Remove the l eft front ki ck panel for access to
the park brake cabl e and park brake pedal assembl y.
(8) Li ft fl oor mat for access to park brake cabl e
and fl oor pan. Pul l the seal and the park brake cabl e
(Fi g. 161) out of the fl oor pan of vehi cl e.
(9) Pul l park brake cabl e strand end forward and
di sconnect button from cl evi s. Tap cabl e housi ng end
fi tti ng out of pedal assembl y bracket.
(10) Remove cabl e retai ner from the park brake
pedal assembl y bracket.
(11) Pul l park brake cabl e assembl y out of vehi cl e
through hol e i n fl oor pan.
INSTALL
(1) Pass park brake cabl e assembl y through hol e
i n fl oor pan from the i nsi de of the vehi cl e.
(2) Pass cabl e strand button through the hol e i n
the pedal assembl y bracket.
(3) I nstal l cabl e retai ner onto the park brake cabl e
and then i nstal l cabl e retai ner i nto pedal assembl y
bracket.
(4) I nstal l the end of the park brake cabl e i nto the
retai ner previ ousl y i nstal l ed i nto the park brake
pedal bracket.
(5) I nstal l cabl e strand button i nto the cl evi s on
(6) I nstal l the front park brake cabl e fl oor pan seal
i nto hol e i n fl oor pan. Seal i s to be i nstal l ed so the
fl ange on the seal i s fl ush wi th the fl oor pan (Fi g.
161). Fol d carpeti ng back down on fl oor.
(8) I nsert brake cabl e and housi ng i nto body out-
ri gger bracket maki ng certai n that housi ng retai ner
fi ngers l ock the housi ng fi rml y i nto pl ace (Fi g. 160).
Fig. 160 Front Park Brake Cable Attachment To
Body
Fig. 161 Front Park Brake Cable At Floor Pan
NS BRAKES 5 - 65
(9) Assembl e the park brake cabl es onto the park
brake cabl e equal i zer (Fi g. 159).
(10) Rel ease the automati c adjuster mechani sm on
the park brake pedal assembl y. Refer to Parki ng
Brake Automati c Adjuster i n the Servi ce Procedures
Secti on i n thi s group of the servi ce manual for the
requi red procedure.
(11) Lower vehi cl e and appl y the park brake pedal
1 ti me, thi s wi l l seat the park brake cabl es.
INTERMEDIATE PARK BRAKE CABLE
REMOVE
(2) Manual l y l ockout the automati c sel f adjusti ng
mechani sm of the park brake pedal assembl y. Refer
to Manual Lockout Of Auto Adjuster Mechani sm i n
thi s secti on of the servi ce manual for the requi red
procedure.
(3) Remove the i ntermedi ate park brake cabl e
from the park brake cabl e equal i zer (Fi g. 162).
from the cabl e connector attachi ng i t to the ri ght
rear park brake cabl e (Fi g. 163)
from the cabl e gui des on the frame rai l s (Fi g. 163).
INSTALL
(1) I nstal l the ends of the park brake cabl es
through the cabl e gui des.
(2) I nstal l the i ntermedi ate park brake cabl e on
the cabl e connector at the ri ght rear park brake cabl e
(Fi g. 163).
(3) I nstal l the i ntermedi ate park brake cabl e on
the cabl e equal i zer (Fi g. 162).
brake cabl e. Thi s wi l l acti vate the automati c adjuster
and correctl y adjust the park brake cabl es.
(5) I nstal l and posi ti on the foam col l ar on the park
brake cabl e to prevent i t from rattl i ng agai nst fl oor.
(6) Lower vehi cl e and appl y the park brake pedal
1 ti me, thi s wi l l seat the park brake cabl es.
RIGHT REAR PARK BRAKE CABLE
REMOVE
(2) Remove rear ti re and wheel assembl y.
(3) Remove rear brake drum from the rear wheel
of the vehi cl e requi ri ng servi ce to the rear park
brake cabl e.
(4) Create sl ack i n the rear park brake cabl es by
l ocki ng out the automati c adjuster as descri bed.
Grasp exposed secti on of front park brake cabl e and
pul l down on i t. Then i nstal l a pai r of l ocki ng pl i ers
on the cabl e just rearward of the second body outri g-
ger bracket (Fi g. 164).
(5) Di sconnect the ri ght rear park brake cabl e
from the connector on the i ntermedi ate cabl e (Fi g.
165).
(6) To remove the ri ght park brake cabl e housi ng
from the body bracket, sl i de a 14 mm box end wrench
over the end of cabl e retai ner to compress the retai n-
i ng fi ngers (Fi g. 166). The al ternate method usi ng an
ai rcraft type hose cl amp wi l l not work on the ri ght
si de of the vehi cl e.
(7) Remove the brake shoes from the brake sup-
port pl ate. Refer to Rear Brake Shoes i n the Removal
And I nstal l ati on Secti on of thi s servi ce manual for
the requi red procedure.
Fig. 163 Intermediate Cable Attachment To Right
Rear Cable
5 - 66 BRAKES NS
(8) Di sconnect park brake cabl e from park brake
actuator l ever.
(9) Remove the park brake cabl e housi ng retai ner
from the brake support pl ate usi ng a 14mm wrench
to compress the retai ni ng fi ngers (Fi g. 167).
INSTALL
(1) I nstal l the park brake cabl e i n the brake sup-
port pl ate. I nsert cabl e housi ng retai ner i nto brake
support pl ate maki ng certai n that cabl e housi ng
retai ner fi ngers l ock the housi ng and retai ner fi rml y
i nto pl ace.
(2) Attach the park brake cabl e onto the park
brake actuator l ever.
(3) I nstal l the brake shoes on the rear brake sup-
(4) I nsert cabl e housi ng retai ner i nto body bracket
maki ng certai n that cabl e housi ng retai ner fi ngers
l ock the housi ng fi rml y i nto pl ace.
(5) Connect the ri ght rear park brake cabl e to the
connector on the i ntermedi ate park brake cabl e (Fi g.
165).
(6) I nstal l the brake drum, and the wheel and ti re
assembl y.
brake cabl e. Thi s wi l l automati cal l y adjust the park
brake cabl es.
(8) Appl y and rel ease park brake pedal 1 ti me,
thi s wi l l seat the park brake cabl es.
LEFT REAR PARK BRAKE CABLE
REMOVE
(2) Remove rear ti re and wheel assembl y.
Fig. 165 Right Rear Cable Connection To
Intermediate Cable
Fig. 166 Right Park Brake Cable Removal From
Body Bracket
Support Plate
NS BRAKES 5 - 67
(3) Remove rear brake drum from the rear wheel
of the vehi cl e requi ri ng servi ce to the rear park
brake cabl e.
(4) Create sl ack i n rear park brake cabl es by l ock-
i ng out the automati c adjuster as descri bed. Grasp
exposed secti on of front park brake cabl e and pul l
down on i t. Then i nstal l a pai r of l ocki ng pl i ers on
the cabl e just rearward of the second body outri gger
bracket (Fi g. 168).
(5) Di sconnect the l eft rear park brake cabl e from
the park brake cabl e equal i zer (Fi g. 169).
(6) To remove park brake cabl e housi ng from the
body bracket, sl i de a 14 mm box end wrench over
retai ner end compressi ng the three fi ngers (Fi g. 170).
cl amp.
(7) Remove the brake shoes from the brake sup-
(8) Di sconnect park brake cabl e from park brake
actuator l ever.
(9) Remove the park brake cabl e housi ng retai ner
from the brake support pl ate usi ng a 14mm wrench
to compress the retai ni ng fi ngers (Fi g. 171).
INSTALL
(1) I nstal l the park brake cabl e i n the brake sup-
port pl ate. I nsert cabl e housi ng retai ner i nto brake
support pl ate maki ng certai n that cabl e housi ng
retai ner fi ngers l ock the housi ng and retai ner fi rml y
i nto pl ace.
(2) Attach the park brake cabl e onto the park
brake actuator l ever.
(3) I nstal l the brake shoes on the rear brake sup-
Fig. 168 Locked Out Park Brake Automatic Adjuster
Fig. 169 Rear Park Brake Cables At Equalizer
Fig. 170 Park Brake Cable Removal From Body
Bracket
Support Plate
5 - 68 BRAKES NS
(4) I nsert cabl e housi ng retai ner i nto body outri g-
ger bracket maki ng certai n that cabl e housi ng
retai ner fi ngers l ock the housi ng fi rml y i nto pl ace.
(5) Connect rear park brake cabl e to the equal i zer
bracket (Fi g. 169).
(6) I nstal l brake drum, and wheel and ti re assem-
bl y.
brake cabl e. Thi s wi l l automati cal l y adjust the park
brake cabl es.
(8) Appl y and rel ease park brake pedal 1 ti me,
thi s wi l l seat the park brake cabl es.
STOP LAMP SWITCH
REMOVE
(1) Depress and hol d the brake pedal whi l e rotat-
i ng stop l amp swi tch (Fi g. 172) i n a counter-cl ockwi se
di recti on approxi matel y 30 degrees.
(2) Pul l the swi tch rearward and remove from i ts
mounti ng bracket.
(3) Di sconnect wi ri ng harness connector from stop
l amp swi tch.
INSTALL
NOTE: Prior to installing stop lamp switch into
bracket, the plunger must be moved to its fully
extended position using procedure in Step 1.
(1) Hol d stop l amp swi tch fi rml y i n one hand.
Then usi ng other hand, pul l outward on the pl unger
of the stop l amp swi tch unti l i t has ratcheted out to
i ts ful l y extended posi ti on.
(2) Connect the wi ri ng harness connector to the
stop l amp swi tch.
(3) Mount the stop l amp swi tch i nto the bracket
usi ng the fol l owi ng procedure. Depress the brake
pedal as far down as possi bl e. Then i nstal l swi tch i n
bracket by al i gni ng i ndex key on swi tch wi th sl ot at
top of square hol e i n mounti ng bracket. When swi tch
i s ful l y i nstal l ed i n bracket, rotate swi tch cl ockwi se
approxi matel y 30 to l ock swi tch i nto bracket.
CAUTION: Do not use excessive force when pulling
back on brake pedal to adjust the stop lamp switch.
If to much force is used, damage to the stop lamp
switch or striker (Fig. 172) can result.
(4) Gentl y pul l back on brake pedal unti l the pedal
stops movi ng. Thi s wi l l cause the swi tch pl unger to
ratchet backward to the correct posi ti on.
MASTER CYLINDER TO POWER BRAKE BOOSTER
VACUUM SEAL
(1) Remove the master cyl i nder from the power
brake vacuum booster. Refer to Master Cyl i nder
removal , for the requi red procedure to remove master
cyl i nder from power brake vacuum booster.
fl ange.
(3) Usi ng Mopar Brake Parts Cl eaner or an equi v-
al ent, thoroughl y cl ean end of master cyl i nder hous-
i ng and master cyl i nder push rod.
(4) I nstal l new master cyl i nder to power brake
booster vacuum seal on master cyl i nder. When
installing new vacuum seal, be sure it is
squarely seated against master cylinder mount-
ing flange and in groove of push rod (Fig. 173).
(5) Bl eed the master cyl i nder assembl y pri or to
i nstal l i ng i t on the power brake vacuum booster.
(6) I nstal l master cyl i nder assembl y on the power
brake vacuum booster. Refer to Master Cyl i nder
I nstal l ati on for the requi red procedure to i nstal l the
master cyl i nder on the power brake vacuum booster.
Fig. 172 Stop Lamp Switch
NS BRAKES 5 - 69
(7) Road test vehi cl e to ensure proper operati on of
the vehi cl es power brake system.
MASTER CYLINDER FLUID RESERVOIR
(1) Cl ean master cyl i nder housi ng and brake fl ui d
reservoi r. Use onl y a sol vent such as Mopar Brake
Parts Cl eaner or an equi val ent.
(2) Remove the fi l l er tube and brake fl ui d reser-
voi r cap. Usi ng a syri nge or equi val ent type tool
empty as much brake fl ui d as possi bl e from the res-
ervoi r.
CAUTION: When removing fluid reservoir from the
master cylinder, do not pry off using any type of
tool. This can damage the fluid reservoir or master
cylinder housing.
(3) Remove the master cyl i nder assembl y from the
power brake vacuum booster. Refer to master cyl i n-
der, i n the removal and i nstal l ati on secti on i n thi s
group of the servi ce manual for the requi red proce-
dure
(4) Mount the master cyl i nder i n a vi se usi ng the
master cyl i nder mounti ng fl ange (Fi g. 174).
(5) Usi ng correct si ze pi n punch, remove the 2
retai ni ng pi ns between the fl ui d reservoi r and master
cyl i nder housi ng (Fi g. 175). Rock the brake fl ui d res-
ervoi r from si de to si de whi l e pul l i ng up to remove i t
from the seal grommets i n master cyl i nder housi ng.
(6) Remove the 2 master cyl i nder housi ng to brake
fl ui d reservoi r seal grommets (Fi g. 176).
(7) I nstal l new master cyl i nder housi ng to brake
fl ui d reservoi r seal i ng grommets (Fi g. 176) i n master
cyl i nder housi ng.
(8) Lubri cate reservoi r mounti ng area wi th fresh
cl ean brake fl ui d. Pl ace reservoi r i n posi ti on over
seal i ng grommets. Seat reservoi r i nto seal i ng grom-
mets usi ng a rocki ng moti on whi l e fi rml y pressi ng
down on fl ui d reservoi r.
(9) Be sure fl ui d reservoi r i s posi ti oned properl y on
master cyl i nder. Bottomof fluid reservoir is to be
touching the top of both sealing grommets
when properly installed on master cylinder
housing.
(10) I nstal l the 2 fl ui d reservoi r to master cyl i nder
retai ni ng pi ns (Fi g. 175).
(11) I nstal l the master cyl i nder assembl y on the
power brake vacuum booster. Refer to master cyl i n-
der, i n the removal and i nstal l ati on secti on i n thi s
group of the servi ce manual for the requi red proce-
dure
(12) I nstal l fi l l er tube on the fl ui d reservoi r. Fi l l
fl ui d reservoi r to i ts proper l evel as i ndi cated on the
outboard si de of the fl ui d reservoi r. Be careful not
to over fill the fluid reservoir, fluid is not
intended to be stored in the filler tube. Install
cap on fluid reservoir filler tube.
Fig. 174 Master Cylinder Correctly Mounted In Vise
Fig. 175 Fluid Reservoir Retaining Pins
Fig. 176 Master Cylinder To Fluid Reservoir Seal
Grommets
5 - 70 BRAKES NS
MASTER CYLINDER FLUID RESERVOIR FILL TUBE
The master cyl i nder fl ui d reservoi r fi l l er neck i s
removabl e from the master cyl i nder fl ui d reservoi r.
The fi l l er neck i f requi red, can be repl aced as a sep-
arate component of the fl ui d reservoi r.
The fi l l er neck i s removed and i nstal l ed usi ng the
fol l owi ng procedure.
REMOVE
(1) Check brake fl ui d l evel i n master cyl i nder fl ui d
reservoi r to be sure brake fl ui d i s not i n the fi l l er
neck. I f brake fl ui d i s i n fi l l er neck, l ower fl ui d l evel
before removi ng fi l l er neck from fl ui d reservoi r
(2) Grasp fi l l er neck at cap end (Fi g. 177) and
push strai ght down. Thi s wi l l cause the fi l l er neck to
pop out of the fl ui d reservoi r.
INSTALL
(1) Wet the O-ri ng on the reservoi r end of the fi l l er
neck wi th fresh cl ean brake fl ui d.
(2) Posi ti on the fi l l er neck i n the openi ng on the
fl ui d reservoi r. Ensure tab on fi l l er neck (Fi g. 177) i s
i n the groove on the front of the fl ui d reservoi r.
(3) Push down whi l e sl i ghtl y rocki ng fi l l er neck
unti l fi l l er neck snaps i nto the fl ui d reservoi r open-
i ng.
(4) I nstal l cap on fi l l er neck.
(5) Check and/or add brake fl ui d i n reservoi r to
ensure i t i s at the correct l evel .
MASTER CYLINDER BRAKE FLUID LEVEL SWITCH
The master cyl i nder or brake fl ui d reservoi r does
not have to be removed from the vehi cl e for repl ace-
ment of the brake fl ui d l evel sensor.
fl ui d reservoi r l evel sensor (Fi g. 178).
(2) Usi ng fi ngers, compress the retai ni ng tabs on
the end of brake fl ui d l evel swi tch (Fi g. 179).
(3) Wi th retai ni ng tabs compressed, (Fi g. 179)
grasp opposi te end of brake fl ui d l evel swi tch and
pul l i t out of master cyl i nder brake fl ui d reservoi r.
(4) I nsert the repl acement brake fl ui d l evel sensor
i nto brake fl ui d reservoi r. Be sure sensor i s pushed
i n unti l retai ni ng tabs (Fi g. 179) l ock i t to the brake
fl ui d reservoi r.
(5) Connect the vehi cl e wi ri ng harness connector
to the brake fl ui d l evel sensor (Fi g. 178).
FRONT DISC BRAKE CALIPER
Check for brake fl ui d l eaks i n and around dust
boot area and i nboard brake pad, and for any rup-
tures, bri ttl eness or damage to the pi ston dust boot.
I f the dust boot i s damaged, or a fl ui d l eak i s vi si bl e,
di sassembl e cal i per assembl y and i nstal l a new pi s-
ton seal and dust boot, and pi ston i f scored. Refer to
Cal i per Di sassembl y And Re-Assembl y Procedures i n
Di sc Brake Cal i per Servi ce i n thi s secti on of the ser-
vi ce manual .
Fig. 177 Master Cylinder Fluid Reservoir Filler Neck
Fig. 179 Master Cylinder Brake Fluid Level Sensor
NS BRAKES 5 - 71
Check the gui de pi n dust boots to determi ne i f they
are i n good condi ti on. Repl ace i f they are damaged,
dry, or found to be bri ttl e. Refer to Gui de Pi n Bush-
i ng Servi ce i n Di sc Brake Cal i per Servi ce i n thi s sec-
ti on of the servi ce manual .
CALIPER GUIDE PIN BUSHING SERVICE
The doubl e pi n cal i per uses a seal ed for l i fe bush-
i ng and sl eeve assembl y. I f requi red thi s assembl y
can be servi ced usi ng the fol l owi ng procedure.
REMOVING CALIPER GUIDE PIN BUSHINGS
(1) Remove cal i per from brake rotor (See Brake
Shoe Removal ). Hang cal i per assembl y on a wi re
hook away from the brake rotor.
(2) Push out and then pul l the steel sl eeve from
the i nsi de of the bushi ng usi ng your fi ngers as shown
i n (Fi g. 180).
(3) Usi ng your fi ngers, col l apse one si de of the
bushi ng. Then pul l on the opposi te si de to remove
the bushi ng from the brake cal i per housi ng (Fi g.
181).
INSTALLING CALIPER GUIDE PIN BUSHINGS
(1) Fol d the bushi ng i n hal f l engthwi se at the sol i d
mi ddl e secti on of the bushi ng (Fi g. 182).
(2) I nsert the fol ded bushi ng i nto the cal i per hous-
i ng (Fi g. 183). Do not use a sharp object to per-
form this step due to possible damage to the
bushing.
(3) Unfol d the bushi ng usi ng your fi ngers or a
wooden dowel unti l the bushi ng i s ful l y seated i nto
the cal i per housi ng. Fl anges shoul d be seated evenl y
on both si des of the bushi ng hol e (Fi g. 184).
(4) Lubri cate the i nsi de surfaces of the bushi ng
usi ng Mopar, Si l i cone Di el ectri c Compound or an
equi val ent.
(5) I nstal l gui de pi n sl eeve i nto one end of bushi ng
unti l seal area of bushi ng i s past seal groove i n
sl eeve (Fi g. 185).
(6) Hol di ng convol uted boot end of bushi ng wi th
one hand, push steel sl eeve bushi ng through boot
unti l one end of bushi ng i s ful l y seated i nto seal
groove on one end of sl eeve (Fi g. 185).
(7) Hol di ng sl eeve i n pl ace, work other end of
bushi ng over end of sl eeve and i nto the seal grove on
sl eeve (Fi g. 186). Be sure other end of bushi ng di d
not come out of seal grove i n sl eeve.
Fig. 180 Removing Inner Sleeve From Bushing
Fig. 181 Removing Bushing From Caliper
Fig. 182 Folded Caliper Guide Pin Bushing
5 - 72 BRAKES NS
(8) When the sl eeve i s seated properl y i nto the
bushi ng, the seal ed for l i fe sl eeve/bushi ng can be
hel d between your fi ngers and easi l y sl i d back and
forth wi thout the bushi ng unseati ng from the sl eeve
groove.
CALIPER DISASSEMBLY
WARNING: UNDER NO CONDITION SHOULD AIR
PRESSURE EVER BE USED TO REMOVE A PISTON
FROM A CALIPER BORE. PERSONAL INJURY
COULD RESULT FROM SUCH A PRACTICE.
(1) Remove cal i per from brake rotor (See Brake
Shoe Removal ). Hang assembl y on a wi re hook away
Fig. 183 Installing Caliper Guide Pin Bushing
Fig. 184 Bushing Correctly Installed In Caliper
Fig. 185 Installing Sleeve In Bushing
Fig. 186 Correctly Installed Caliper Sleeve And
Bushing
NS BRAKES 5 - 73
from rotor, so hydraul i c fl ui d cannot get on rotor.
Pl ace a smal l pi ece of wood between the pi ston and
cal i per fi ngers.
(2) Carefully depress brake pedal to hydraul i cal l y
push pi ston out of bore. Then appl y and hol d down
the brake pedal to any posi ti on beyond the fi rst i nch
of pedal travel . Thi s wi l l prevent l oss of brake fl ui d
from the master cyl i nder.
(3) I f both front cal i per pi stons are to be removed,
di sconnect brake tube at fl exi bl e brake hose at frame
rai l . Pl ug brake tube and remove pi ston from oppo-
si te cal i per usi ng the same process as above for the
fi rst pi ston removal .
(4) Di sconnect the brake fl ui d fl ex hose from the
cal i per assembl y.
CAUTION: Do not use excessive force when clamp-
ing caliper in vise. Excessive vise pressure will
cause bore distortion and binding of piston.
(5) To di sassembl e cal i per, mount i n a vi se
equi pped wi th protecti ve jaws.
(6) Remove gui de pi n sl eeves and gui de pi n bush-
i ngs. See Removi ng Gui de Pi n Bushi ngs i n the cal i -
per di sassembl y secti on of thi s manual .
(7) Remove the pi ston dust boot from the cal i per
and di scard (Fi g. 187).
(8) Usi ng a soft tool , such as a pl asti c tri m sti ck,
work pi ston seal out of i ts groove i n cal i per pi ston
bore (Fi g. 188). Di scard ol d seal . Do not use a
screw driver or other metal tool for this opera-
tion, because of the possibility of scratching
piston bore or burring edges of seal groove.
(9) Cl ean al l parts usi ng al cohol or a sui tabl e sol -
vent and wi pe dry using only a lint free cloth. No
l i nt resi due can remai n i n cal i per bore. Cl ean out al l
dri l l ed passages and bores. Whenever a caliper
has been disassembled, a new boot and seal
must be installed at assembly.
(10) I nspect the pi ston bore for scori ng or pi tti ng.
Bores that show l i ght scratches or corrosi on can usu-
al l y be cl eared of the l i ght scratches or corrosi on
usi ng crocus cl oth. Bores that have deep scratches or
scori ng shoul d be honed. Use Cal i per Hone, Speci al
Tool C-4095, or equi val ent provi di ng the di ameter of
the bore i s not i ncreased more than 0.0254 mm
(0.001 i nch) (Fi g. 189).
(11) I f the bore does not cl ean up wi thi n thi s spec-
i fi cati on, a new cal i per housi ng shoul d be i nstal l ed.
I nstal l a new pi ston i f the ol d one i s pi tted or scored.
NOTE: When using Caliper Honing Tool, Special
Tool C-4095, coat the stones and bore with brake
fluid. After honing the bore, carefully clean the seal
and boot grooves with a stiff non-metallic rotary
brush.
NOTE: Use extreme care in cleaning the caliper
after honing. Remove all dirt and grit by flushing
the caliper with brake fluid; wipe dry with a clean,
lint free cloth and then clean a second time.
CAUTION: When inspecting caliper piston, do not
use anything but solvents to clean piston surface. If
surface of piston cannot be cleaned using only sol-
vents, piston must be replaced.
Fig. 187 Removing Caliper/Piston Dust Boot
Fig. 188 Removing Piston Seal From Caliper
5 - 74 BRAKES NS
(12) I nspect cal i per pi ston for pi tti ng, scratches, or
any physi cal damage. Repl ace pi ston i f there i s evi -
dence of scratches, pi tti ng or physi cal damage.
CALIPER ASSEMBLY
CAUTION: Excessive vise pressure will cause bore
distortion and binding of piston.
(1) Cl amp cal i per i n a vi se (wi th protecti ve caps
i nstal l ed on jaws of vi se).
(2) Di p new pi ston seal i n cl ean brake fl ui d and
i nstal l i n the groove of the cal i per bore. Seal shoul d
be posi ti oned at one area i n groove and gentl y
worked around the groove (Fi g. 190), usi ng onl y your
fi ngers unti l properl y seated. NEVER USE AN OLD
PISTON SEAL. Be sure that fi ngers are cl ean and
seal i s not twi sted or rol l ed (Fi g. 190).
(3) Coat new pi ston boot wi th cl ean brake fl ui d
l eavi ng a generous amount i nsi de boot.
(4) Posi ti on dust boot over pi ston after coati ng
wi th brake fl ui d.
CAUTION: Force must be applied to the piston uni-
formly to avoid cocking and binding of the piston in
the bore of the caliper.
(5) I nstal l pi ston i nto cal i per bore pushi ng i t past
the pi ston seal unti l i t bottoms i n the cal i per bore
(Fi g. 191).
(6) Posi ti on dust boot i nto the counterbore of the
cal i per assembl y pi ston bore.
(7) Usi ng a hammer and I nstal l er Pi ston Cal i per
Boot, Speci al Tool C-4689 and Handl e, Speci al Tool
C-4171, dri ve boot i nto counterbore of the cal i per
(Fi g. 192).
(8) I nstal l gui de pi n sl eeves and bushi ngs. See
I nstal l Gui de Pi n Bushi ngs secti on i n the cal i per di s-
assembl y secti on of thi s manual .
(9) I nstal l brake pads. See I nstal l i ng Brake Pads
i n the Brake Pad Servi ce Procedures secti on of thi s
manual .
(10) Before i nstal l i ng cal i per assembl y on vehi cl e,
i nspect brake rotor. I f any condi ti ons as descri bed i n
Checki ng Brake Rotor for Runout and Thi ckness are
present the rotor, must be repl aced or refaced. I f the
rotor does not requi re any servi ci ng, i nstal l cal i per
assembl y.
(11) I nstal l brake hose onto cal i per usi ng banjo
bol t. Torque the brake hose to cal i per assembl y banjo
bol t to 33 Nm (24 ft. l bs.). New seal washers
Fig. 189 Honing Brake Caliper Piston Bore
Fig. 190 Installing New Piston Seal In Caliper
Fig. 191 Installing Piston Into Caliper Bore
NS BRAKES 5 - 75
MUST always be used when installing brake
hose to caliper.
(12) Bl eed the brake system (see Bl eedi ng Brake
System).
WHEEL CYLINDER REAR DRUM BRAKE
DISASSEMBLE
To di sassembl e the wheel cyl i nders, proceed as fol -
l ows:
(1) Pry boots away from cyl i nders and remove (Fi g.
193).
(2) Press IN on one pi ston to force out opposi te
pi ston, cup and spri ng (Fi g. 193). Then usi ng a soft
tool such as a dowel rod, press out the cup and pi ston
that remai n i n the wheel cyl i nder.
(3) Wash wheel cyl i nder, pi stons, and spri ng (Fi g.
193) i n cl ean brake fl ui d or al cohol ; (DO NOT USE
ANY PETROLEUM BASE SOLVENTS) cl ean thor-
oughl y and bl ow dry wi th compressed ai r. I nspect cyl -
i nder bore and pi ston for scori ng and pi tti ng. (Do not
use a rag as l i nt from the rag wi l l sti ck to bore sur-
faces.)
(4) Wheel cyl i nder bores and pi stons that are
badl y scored or pi tted shoul d be repl aced. Cyl i nder
wal l s that have l i ght scratches, or show si gns of cor-
rosi on, can usual l y be cl eaned wi th crocus cl oth,
usi ng a ci rcul ar moti on. Bl ack stai ns on the cyl i nder
wal l s are caused by pi ston cups and wi l l not i mpai r
operati on of cyl i nder.
ASSEMBLE
Before assembl i ng the pi stons and new cups i n the
wheel cyl i nders, di p them i n cl ean brake fl ui d. I f the
boots are deteri orated, cracked or do not fi t ti ghtl y on
the pi stons or the cyl i nder casti ng, i nstal l new boots.
(1) Coat cyl i nder bore wi th cl ean brake fl ui d.
(2) Li ghtl y coat the seal i ng l i p and outer surfaces
of the wheel cyl i nder cups wi th only Mopar Pro-
tect-A-Cup Lubricant p/n 04883068 and no sub-
stitute.
(3) I nstal l expansi on spri ng wi th cup expanders i n
cyl i nder. I nstal l cups i n each end of cyl i nder wi th
open end of cups faci ng each other (Fi g. 193).
(4) I nstal l pi ston i n each end of cyl i nder havi ng
the fl at face of each pi ston contacti ng the fl at face of
each cup, al ready i nstal l ed (Fi g. 193).
(5) I nstal l a boot over each end of cyl i nder (Fi g.
193). Be careful not to damage boot during
installation.
FRONT DISC BRAKE PAD LINING INSPECTION
I f a vi sual i nspecti on does not adequatel y deter-
mi ne the condi ti on of the l i ni ng, a physi cal check wi l l
be necessary. To check the amount of l i ni ng wear,
remove the wheel and ti re assembl i es, and the cal i -
pers.
Remove the shoe and l i ni ng assembl i es. (See Brake
Shoe Removal ).
Combi ned shoe and l i ni ng thi ckness shoul d be
measured at the thi nnest part of the brake shoe
assembl y.
When a shoe and l i ni ng assembl y i s worn to a
thi ckness of approxi matel y 7.95 mm (0.313 i nch) i t
shoul d be repl aced.
Repl ace both shoe assembl i es (i nboard and out-
board) on the front wheel s. I t i s al so necessary that
both front wheel brake shoe assembl y sets be
repl aced, whenever shoe assembl i es on ei ther si de of
the vehi cl e requi re repl acement.
I f a shoe assembl y does not requi re repl acement,
rei nstal l i t, maki ng sure each shoe assembl y i s
returned to i ts ori gi nal posi ti on. (See Brake Shoe
I nstal l ati on).
REAR DISC BRAKES
BRAKE PAD LINING WEAR
I f a vi sual i nspecti on does not adequatel y deter-
mi ne the condi ti on of the l i ni ng, a physi cal check wi l l
be necessary. To check the amount of l i ni ng wear,
remove the wheel and ti re assembl i es, and the cal i -
pers.
Remove the rear di sc brake shoes. Refer to Rear
Di sc Brake Shoe Removal i n the Removal And I nstal -
Fig. 192 Installing Dust Boot In Caliper Counterbore
5 - 76 BRAKES NS
l ati on secti on i n thi s group of the servi ce manual for
The combi ned brake shoe and l i ni ng materi al
thi ckness shoul d be measured at the thi nnest part of
the assembl y.
When a set of brake shoes are worn to a total
thi ckness of approxi matel y 7.0 mm (9/32 i nch) they
shoul d be repl aced.
Repl ace both brake shoe assembl i es (i nboard and
outboard). I t i s necessary that both rear wheel sets
be repl aced whenever brake shoe assembl i es on
ei ther si de are repl aced.
I f the brake shoe assembl i es do not requi re
repl acement, rei nstal l , the assembl i es maki ng sure
each brake shoe i s returned to the ori gi nal posi ti on.
Refer to Rear Di sc Brake Shoe I nstal l ati on i n the
Removal And I nstal l ati on secti on i n thi s group of the
CALIPER INSPECTION
Check for brake fl ui d l eaks i n and around boot
area and i nboard l i ni ng, and for any ruptures, bri t-
tl eness or damage to the pi ston dust boot. I f the boot
i s damaged, or a fl ui d l eak i s vi si bl e, di sassembl e cal -
i per assembl y and i nstal l a new seal and boot, and
pi ston i f scored. Refer to Rear Di sc Brake Cal i per i n
the Di sassembl y And Assembl y Secti on i n thi s group
Check the gui de pi n dust boots to determi ne i f they
are i n good condi ti on. Repl ace i f they are damaged,
dry, or found to be bri ttl e. Refer to Rear Di sc Brake
Cal i per i n the Di sassembl y And Assembl y Secti on i n
REAR DRUM BRAKE SHOE LINING INSPECTION
vehi cl e
(2) Remove the rear brake adjusti ng hol e cover
pl ug (Fi g. 194).
(3) I nsert a thi n screwdri ver i nto brake adjusti ng
hol e to hol d the adjusti ng l ever away from the
notches on the adjusti ng screw star wheel .
(4) I nsert Tool C-3784 i nto brake adjusti ng hol e
and engage notches of brake adjusti ng screw star
wheel . Rel ease brake by pryi ng down wi th adjusti ng
tool .
(5) Remove the rear brake drum from the rear
hub/beari ng assembl y.
(6) I nspect brake l i ni ng for wear, shoe al i gnment,
and or contami nati on from grease or brake fl ui d.
Fig. 193 Rear Wheel Cylinder (Exploded View)
Fig. 194 Brake Adjustment Hole Rubber Plug
NS BRAKES 5 - 77
CLEANING AND INSPECTION (Continued)
REAR DRUM BRAKE WHEEL CYLINDER
Wi th brake drums removed, i nspect the wheel cyl -
i nder boots for evi dence of a brake fl ui d l eak. Vi su-
al l y check the boots for cuts, tears, or heat cracks. I f
any of these condi ti ons exi st, the wheel cyl i nders
shoul d be compl etel y cl eaned, i nspected and new
parts i nstal l ed.
I f a wheel cyl i nder i s l eaki ng and the brake l i ni ng
materi al i s saturated wi th brake fl ui d, the brake
shoes must be repl aced.
BRAKE HOSE AND BRAKE LINES INSPECTION
Fl exi bl e rubber hose i s used at both front brakes
and at the rear axl e. I nspecti on of brake hoses
shoul d be performed whenever the brake system i s
servi ced and every 7,500 mi l es or 12 months, whi ch-
ever comes fi rst (every engi ne oi l change). I nspect
hydraul i c brake hoses for surface cracki ng, scuffi ng,
or worn spots. I f the fabri c casi ng of the rubber hose
becomes exposed due to cracks or abrasi ons i n the
rubber hose cover, the hose shoul d be repl aced i mme-
di atel y. Eventual deteri orati on of the hose can take
pl ace wi th possi bl e burst fai l ure. Faul ty i nstal l ati on
can cause twi sti ng, resul ti ng i n wheel , ti re, or chassi s
i nterference.
The steel brake tubi ng shoul d be i nspected peri od-
i cal l y for evi dence of physi cal damage or contact wi th
movi ng or hot components.
The fl exi bl e brake tube secti ons used on thi s vehi -
cl e i n the pri mary and secondary tubes from the
master cyl i nder to the ABS hydraul i c control uni t
connecti ons and the chassi s brake tubes between the
hydraul i c control uni t and the proporti oni ng val ve
must al so be i nspected. Thi s fl exi bl e tubi ng must be
i nspected for ki nks, frayi ng and i ts contact wi th
other components of the vehi cl e or contact wi th the
body of the vehi cl e.
REAR WHEEL HUB AND BEARING ASSEMBLY
The rear hub and beari ng assembl y i s desi gned for
the l i fe of the vehi cl e and shoul d requi re no mai nte-
nance. The fol l owi ng procedure may be used for eval -
uati on of beari ng condi ti on.
Wi th wheel and brake drum removed, rotate
fl anged outer ri ng of hub. Excessi ve roughness, l at-
eral pl ay or resi stance to rotati on may i ndi cate di rt
i ntrusi on or beari ng fai l ure. I f the rear wheel bear-
i ngs exhi bi t these condi ti ons duri ng i nspecti on, the
hub and beari ng assembl y shoul d be repl aced.
Damaged beari ng seal s and resul ti ng excessi ve
grease l oss may al so requi re beari ng repl acement.
Moderate grease l oss from beari ng i s consi dered nor-
mal and shoul d not requi re repl acement of the hub
and beari ng assembl y.
ADJ USTMENTS
STOP LAMP SWITCH
(1) Remove stop l amp swi tch from i ts bracket by
rotati ng i t approxi matel y 30 i n a counter-cl ockwi se
di recti on.
(2) Di sconnect wi ri ng harness connector from stop
l amp swi tch.
(3) Hol d stop l amp swi tch fi rml y i n one hand.
Then usi ng other hand, pul l outward on the pl unger
of the stop l amp swi tch unti l i t has ratcheted out to
i ts ful l y extended posi ti on.
(4) I nstal l the stop l amp swi tch i nto the bracket
usi ng the fol l owi ng procedure. Depress the brake
pedal as far down as possi bl e. Then whi l e keepi ng
the brake pedal depressed, i nstal l the stop l amp
swi tch i nto the bracket by al i gni ng i ndex key on
swi tch wi th sl ot at top of square hol e i n mounti ng
bracket. When swi tch i s ful l y i nstal l ed i n the square
hol e of the bracket, rotate swi tch cl ockwi se approxi -
matel y 30 to l ock the swi tch i nto the bracket.
CAUTION: Do not use excessive force when pulling
back on brake pedal to adjust the stop lamp switch.
If too much force is used, damage to the vacuum
booster, stop lamp switch or striker (Fig. 195) can
result.
(5) Connect the wi ri ng harness connector to the
stop l amp swi tch.
(6) Gentl y pul l back on brake pedal unti l the pedal
stops movi ng. Thi s wi l l cause the swi tch pl unger
(Fi g. 195) to ratchet backward to the correct posi ti on.
Fig. 195 Stop Light Switch Location In Vehicle
5 - 78 BRAKES NS
REAR DRUM BRAKE SHOE ADJUSTMENT
NOTE: Normally, self adjusting drum brakes will
not require manual brake shoe adjustment.
Although in the event of a brake reline it is advis-
able to make the initial adjustment manually to
speed up the adjusting time.
(1) Rai se the vehi cl e so that the rear wheel s are
free to turn. See Hoi sti ng Recommendati ons i n the
Lubri cati on And Mai ntenance Secti on, at the front of
(2) Remove rubber pl ug, from rear brake adjusti ng
hol e, i n the rear brake support pl ate (Fi g. 197).
(3) Be sure parking brake lever is fully
released.
(4) I nsert Brake Adjusti ng, Speci al Tool C-3784 or
equi val ent through the adjusti ng hol e i n support
pl ate and agai nst star wheel of adjusti ng screw. Move
handl e of tool upward unti l a sl i ght drag i s fel t when
road wheel i s rotated.
(5) I nsert a thi n screwdri ver or pi ece of wel di ng
rod i nto brake adjusti ng hol e. Push adjusti ng l ever
out of engagement wi th star wheel . Care should be
taken so as not to bend adjusting lever or dis-
tort lever spring. Whi l e hol di ng adjusti ng l ever out
of engagement, back off star wheel to ensure a free
wheel wi th no brake shoe drag.
(6) Repeat above adjustment at the other rear
wheel .
(7) I nstal l adjusti ng hol e rubber pl ug (Fi g. 197) i n
rear brake support pl ates.
(8) I nstal l park brake cabl es on park brake cabl e
equal i zer (Fi g. 196).
PARK BRAKE SHOES (WITH REAR DISC BRAKES)
CAUTION: Before adjusting the park brake shoes
be sure that the park brake pedal is in the fully
released position. If park brake pedal is not in the
fully released position, the park brake shoes can
not be accurately adjusted.
(2) Remove ti re and wheel .
(3) Remove di sc brake cal i per from cal i per adapter
(Fi g. 198). I f requi red, refer to Rear Di sc Brake Cal -
i per i n the Removal And I nstal l ati on Secti on i n thi s
group of the servi ce manual for the removal proce-
dure.
Fig. 197 Brake Adjusting Hole Plug
Fig. 198 Disc Brake Caliper
NS BRAKES 5 - 79
ADJ USTMENTS (Continued)
(4) Remove rotor from hub/beari ng.
NOTE: When measuring the brake drum diameter,
the diameter should be measured in the center of
the area in which the park brake shoes contact the
surface of the brake drum.
(5) Usi ng Gauge, Brake Shoe, Speci al Tool C-3919
or an equi val ent, accurately measure the i nsi de
di ameter of the park brake drum porti on of the rotor
(Fi g. 199).
(6) Usi ng a rul er that reads i n 64th of an i nch,
accuratel y read the measurement of the i nsi de di am-
eter of the park brake drum from the speci al tool
(Fi g. 200).
(7) Reduce the i nsi de di ameter measurement of
the brake drum that was taken usi ng Speci al Tool
C-3919 by 1/64 of an i nch. Reset Gauge, Brake Shoe,
Speci al Tool C-3919 or the equi val ent used, so that
the outsi de measurement jaws are set to the reduced
measurement (Fi g. 201).
(8) Pl ace Gauge, Brake Shoe, Speci al Tool C-3919
or equi val ent over the park brake shoes (Fi g. 202).
The speci al tool must be l ocated strai ght across at
the center (wi dest poi nt) of the park brake shoes
(Fi g. 202).
(9) Usi ng the star wheel adjuster, adjust the park
brake shoes unti l the l i ni ng on the park brake shoes
just touches the jaws on the speci al tool .
(10) I nstal l rotor on hub/beari ng.
(11) Rotate rotor to veri fy that the park brake
shoes are not draggi ng on the brake drum. I f park
brake shoes are draggi ng, remove rotor and back off
star wheel adjuster one notch and recheck for brake
shoe drag agai nst drum. Conti nue wi th the previ ous
step unti l brake shoes are not draggi ng on brake
drum.
(12) I nstal l di sc brake cal i per on cal i per adapter
(Fi g. 198). I f requi red, refer to Rear Di sc Brake Cal -
i per i n the Removal And I nstal l ati on Secti on i n thi s
Fig. 199 Measuring Park Brake Drum Diameter
Fig. 200 Reading Park Brake Drum Diameter
Fig. 201 Setting Gauge To Park Brake Shoe
Measurement
Fig. 202 Adjusting Park Brake Shoes
5 - 80 BRAKES NS
group of the servi ce manual for the i nstal l ati on pro-
cedure.
(14) Ti ghten the wheel mounti ng nuts i n the
proper sequence unti l al l nuts are torqued to hal f the
speci fi ed torque. Then repeat the ti ghteni ng sequence
to the ful l speci fi ed torque of 129 Nm (95 ft. l bs.).
(16) Appl y and rel ease the park brake pedal one
ti me. Thi s wi l l seat and correctl y adjust the park
brake cabl es.
CAUTION: Before moving vehicle, pump brake
pedal several times to ensure the vehicle has a firm
enough pedal to stop the vehicle.
(17) Road test the vehi cl e to ensure proper func-
ti on of the vehi cl es brake system.
PARK BRAKE CABLE ADJUSTMENT
The park brake cabl es on thi s vehi cl e have an
automati c sel f adjuster bui l t i nto the park brake
pedal mechani sm. When the foot operated park brake
pedal i s i n i ts rel eased (upward most) posi ti on, a
cl ock spri ng automati cal l y adjusts the park brake
cabl es. The park brake cabl es are adjusted (ten-
si oned) just enough to remove al l the sl ack from the
cabl es. The automati c adjuster system wi l l not over
adjust the cabl es causi ng rear brake drag.
Due to the automati c adjust feature of the park
brake pedal , adjustment of the parki ng brake cabl es
on these vehi cl es rel i es on proper drum brake and
park brake shoe adjustment. See Rear Brake Adjust-
ment and Park Brake Shoe Adjustment i n the Ser-
vi ce Adjustments Secti on i n thi s group of the servi ce
manual .
When the park brake pedal i s appl i ed the sel f
adjuster i s by-passed and the pedal operates nor-
mal l y to engage the park brakes.
When a servi ce procedure needs to be performed on
the park brake pedal or the park brake cabl es, the
automati c sel f adjuster can be manual l y l ocked out
by the servi ce techni ci an.
PROPORTIONING VALVE (HEIGHT SENSING)
Proporti oni ng val ve actuator adjustment wi l l be
requi red i f there i s a compl ai nt of premature rear
wheel l ockup and the front and rear brake shoe l i n-
i ngs checked OK duri ng i nspecti on, the hei ght sens-
i ng proporti oni ng val ve requi red repl acement, or
there i s a compl ai nt of excessi ve pedal effort and the
vacuum booster and brake pedal checked OK. Make
sure the proporti oni ng val ve and the mounti ng
bracket are fi rml y attached to the vehi cl e. Then, pro-
ceed wi th the fol l owi ng procedure to perform the
adjustment of the actuator.
ported on jackstands or wi th a frame contact type
hoi st so the rear suspensi on of the vehi cl e i s hangi ng
free. See hoi sti ng i n the Lubri cati on And Mai nte-
(2) Remove rear wheel s/ti res.
(3) Usi ng an appropri ate jack, support the rear
axl e pri or to the removal of the track bar and shock
absorber bol ts from the rear axl e.
(4) Unbol t the track bar from the rear axl e.
(5) Unbol t both shock absorbers from the rear
axl e.
(6) Loosen (do not remove) both of the l eaf spri ng
to front spri ng hanger pi vot bol ts.
NOTE: When lowering the rear axle be sure that the
leaf springs do not come in contact with the hoist
limiting the downward movement of the axle. If this
occurs an improper adjustment of the actuator may
result.
(7) Lower the rear axl e so i t i s at i ts farthest poi nt
of downward movement.
(8) Loosen the adjustment nut (Fi g. 203) on the
actuator.
(9) Be sure the hooked end of the actuator i s cor-
rectl y (ful l y) seated i n the cl i p on the proporti oni ng
val ve l ever and that the cl i p i s correctl y posi ti oned
on the l ever of the proporti oni ng val ve.
(10) Pul l the housi ng of the proporti oni ng val ve
actuator toward the spri ng hanger (Fi g. 203) unti l
the l ever on the proporti oni ng val ve bottoms on the
body of the proporti oni ng val ve. Hold the propor-
tioning valve actuator in this position while
tightening the adjustment nut (Fig. 203) to a
torque of 5 Nm (45 in. lbs.). Proportioning
valve adjustment is now complete.
(11) I nstal l shock absorbers and track bar on rear
axl e. Do not tighten the mounting bolts for any
of the loosened suspension components at this
time.
(12) I nstal l the wheel /ti res.
Fig. 203 Proportioning Valve Actuator Adjustment
NS BRAKES 5 - 81
(13) Lower the vehi cl e to the ground. Be sure
that the suspension is supporting the full
weight of the vehicle.
(14) Ti ghten the spri ng to front hanger pi vot bol ts
(15) Ti ghten the shock absorber mounti ng bol ts to
a torque of 101 Nm (75 ft. l bs.).
(16) Ti ghten the track bar mounti ng bol t to a
(17) Road test vehi cl e to ensure that the prema-
ture rear wheel l ockup condi ti on has been corrected.
SPECIFICATIONS
BRAKE FLUID
The brake fl ui d used i n thi s vehi cl e must conform
to DOT 3 speci fi cati ons and SAE J1703 standards.
No other type of brake fl ui d i s recommended or
approved for usage i n the vehi cl e brake system. Use
onl y Mopar brake fl ui d or an equi val ent from a
ti ghtl y seal ed contai ner.
CAUTION: Never use reclaimed brake fluid or fluid
from an container which has been left open. An
open container will absorb moisture from the air
and contaminate the fluid.
CAUTION: Never use any type of a petroleum-
based fluid in the brake hydraulic system. Use of
such type fluids will result in seal damage of the
vehicle brake hydraulic system causing a failure of
the vehicle brake system. Petroleum based fluids
would be items such as engine oil, transmission
fluid, power steering fluid ect.
VEHICLE BRAKE SYSTEM COMPONENT SPECIFICATIONS
Brake System Component Specifications
5 - 82 BRAKES NS
BRAKE ACTUATION SYSTEM
ACTUATION:
Vacuum Operated Power Brakes . . . . . . . . .Standard
Hydraul i c System. . . . . . . . . . .Dual -Di agonal l y Spl i t
Anti l ock Brake Sytem (Teves Mark-20) . . . . . . . . . . .
MASTER CYLINDER ASSEMBLY:
Suppl i er . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Bosch
Type For Non-ABSAnd
ABS Brakes . . . .Conventi onal Compensati ng Port
Type For ABS Brakes
Wi th Tracti on Control . . .Dual Center Port Desi gn
Body Materi al . . . . . . . . . . . . . . .Anodi zed Al umi num
Reservoi r Materi al . . . . . . . . . . . . . . . .Pol ypropel ene
MASTER CYLINDER BORE /
STROKE AND SPLIT:
ABS W/Di sc/Drum Brakes . . . . . . 23.8 mm x 36 mm
(.937 i n. x 1.47 i n.)
AWD W/Di sc/Di sc Brakes . . . . . . . .25.4 mm x 39 mm
(1.00 i n. x 1.50 i n.)
Di spl acement Spl i t . . . . . . . . . . . . . . . . . . . . .50 /50
MASTER CYLINDER FLUID OUTLET PORTS:
Non-ABS And ABS . . .Pri mary 7/1624 Secondary 7/
1624
ABS Wi th Tracti on Control . . . . . . .Pri mary M12 x 1
Secondary M12 x 1
Outl et Fi tti ng Type Non-ABS
And ABS . . . . . . . . . . .Doubl e Wal l I nverted Fl are
Outl et Fi tti ng Type ABS Wi th
Tracti on Control . . . . . . . . . . . . . . . . . . .I SO Fl are
ABS HYDRAULIC CONTROL UNIT:
Hydraul i c Tube Fi tti ng Type. . . . . . . . . . . .I SO Fl are
BOOSTER:
Make/Type. . . . . . . . . . . . . . . . .Bosch Vacuum Assi st
Mounti ng Studs . . . . . . . . . . . . . . . . . . . . .M8 x 1.25
Type . . . . . . . . . . . . . . . . . . . . . . . . .270 ZLT RSMV
Boost At 20 i nches Of
Mani fol d Vacuum. . . . . . . . . . .3800 Nm (850 l bs.)
PROPORTIONING VALVE:
Materi al . . . . . . . . . . . . . . . . . . . . . . . . . . .Al umi num
Functi on. . . . . . . . . . . . . . . . . . . .Hydraul i c Pressure
Proporti oni ng To Rear Brakes
BRAKE PEDAL
Pedal Rati o . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.36
BRAKE FASTENER TORQUE SPECIFICATIONS
DESCRIPTION TORQUE
BRAKE TUBES:
Tube Nuts To Fi tti ngs And
Components . . . . . . . . . . . . . .17 Nm (145 i n. l bs.)
BRAKE HOSE:
To Cal i per Banjo Bol t . . . . . . . . . .48 Nm (35 ft. l bs.)
I ntermedi ate Bracket . . . . . . . . .12 Nm (105 i n. l bs.)
MASTER CYLINDER:
To Vacuum Booster
Mounti ng Nut . . . . . . . . . . . .25 Nm (225 i n. l bs.)
FIXED PROPORTIONING VALVE:
To Frame Rai l Attachi ng
Bol ts . . . . . . . . . . . . . . . . . . . .14 Nm (125 i n. l bs.)
HEIGHT SENSING PROPORTIONING VALVE:
To Mounti ng Bracket
Attachi ng Bol ts . . . . . . . . . . .23 Nm (200 i n. l bs.)
Actuator Assembl y
Adjustment Nut . . . . . . . . . . . . .5 Nm (45 i n. l bs.)
Mounti ng Bracket To Frame
Rai l Bol ts . . . . . . . . . . . . . . . .17 Nm (150 i n. l bs.)
J UNCTION BLOCK (NON-ABS BRAKES)
Mounti ng Bol t . . . . . . . . . . . .28 Nm (250 i n. l bs.)
VACUUM BOOSTER:
To Dash Panel Mounti ng
Nuts . . . . . . . . . . . . . . . . . . . .28 Nm (250 i n. l bs.)
REAR WHEEL CYLINDER:
To Support Pl ate Mounti ng
Bol ts . . . . . . . . . . . . . . . . . . . . .8 Nm (75 i n. l bs.)
Bl eeder Screw . . . . . . . . . . . . . . .10 Nm (80 i n. l bs.)
BRAKE SUPPORT PLATE:
To Rear Axl e Mounti ng Bol ts . . .130 Nm (95 ft. l bs.)
DISC BRAKE CALIPER:
Gui de Pi n Bol ts . . . . . . . . . . . . . .41 Nm (30 ft. l bs.)
Bl eeder Screw . . . . . . . . . . . . . .15 Nm (125 i n. l bs.)
Mounti ng Bracket To
Suspensi on Cradl e Bol ts. . . . .28 Nm (250 i n. l bs.)
To Mounti ng Bracket I sol ator
Attachi ng Bol ts . . . . . . . . . . . .11 Nm (97 i n. l bs.)
CAB To HCU Mounti ng Screws . . .2 Nm (17 i n. l bs.)
WHEEL SPEED SENSOR:
To Axl e Or Steeri ng Knuckl e
PARKING BRAKE:
Pedal Assembl y Mounti ng
Bol ts . . . . . . . . . . . . . . . . . . . .28 Nm (250 i n. l bs.)
REAR HUB AND BEARING:
WHEEL:
Stud Lug Nut . . . . . . . .115156 Nm (84-115 ft. l bs.)
NS BRAKES 5 - 83
SPECIAL TOOLS
SPECIAL TOOLS BASE BRAKES
Fittings, Brake Proportioning Valve Testing 6833
Tubes, Master Cylinder Bleeding 6920
Adapter, Master Cylinder Pressure Bleed Cap 6921
Dial Indicator, C-3339
Gauge, Brake Safe-Set
Gauge Set, C-4007A
Fig. 204 Handle, Universal C4171
Fig. 205 Installer, Dust Boot C-4689
5 - 84 BRAKES NS
ANTILOCK BRAKE SYSTEM TEVES MARK-20
INDEX
page page
ABS BRAKE SYSTEM COMPONENTS . . . . . . . . 87
ABS BRAKES COMPONENT
ABBREVIATION LIST . . . . . . . . . . . . . . . . . . . . 85
ABS BRAKES OPERATION AND VEHICLE
PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . 86
ABS FUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
ABS MASTER CYLINDER AND POWER
BRAKE BOOSTER . . . . . . . . . . . . . . . . . . . . . 87
ABS RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
ABS WARNING LAMP (YELLOW) . . . . . . . . . . . . 91
ANTILOCK BRAKES OPERATION
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 85
ASR VALVE (ABS WITH TRACTION
CONTROL ONLY) . . . . . . . . . . . . . . . . . . . . . . 88
CONTROLLER ANTILOCK BRAKES (CAB) . . . . . 90
HCU BRAKE FLUID ACCUMULATORS AND
NOISE DAMPING CHAMBER . . . . . . . . . . . . . 88
HCU PUMP/MOTOR . . . . . . . . . . . . . . . . . . . . . 89
HYDRAULIC CIRCUITS AND VALVE
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 92
INLET VALVES AND SOLENOIDS . . . . . . . . . . . . 88
INTEGRATED CONTROL UNIT (ICU) . . . . . . . . . 87
OUTLET VALVES AND SOLENOIDS . . . . . . . . . . 88
PROPORTIONING VALVES . . . . . . . . . . . . . . . . 89
WHEEL SPEED SENSORS . . . . . . . . . . . . . . . . . 89
ABS BRAKE DIAGNOSTIC TOOL
CONNECTOR . . . . . . . . . . . . . . . . . . . . . . . . . 96
ABS DIAGNOSTIC TROUBLE CODES . . . . . . . . 97
ABS DIAGNOSTICS MANUAL . . . . . . . . . . . . . . 96
ABS GENERAL DIAGNOSTICS
INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . 95
ABS SERVICE PRECAUTIONS . . . . . . . . . . . . . . 99
ABS SYSTEM SELF DIAGNOSTICS . . . . . . . . . . 96
ABS WIRING DIAGRAM INFORMATION . . . . . . . 95
BRAKE FLUID CONTAMINATION . . . . . . . . . . . . 98
DRB DIAGNOSTIC SCAN TOOL USAGE . . . . . . 96
INTERMITTENT DIAGNOSTIC TROUBLE
CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
PROPORTIONING VALVE . . . . . . . . . . . . . . . . . 98
TEST DRIVING ABS COMPLAINT VEHICLE . . . . 98
TONEWHEEL INSPECTION . . . . . . . . . . . . . . . . 98
SERVICE PROCEDURES
BLEEDING TEVES MARK 20 HYDRAULIC
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
BRAKE FLUID LEVEL INSPECTION . . . . . . . . . . 99
ABS GENERAL SERVICE PRECAUTIONS . . . . 100
CONTROLLER ANTILOCK BRAKES (CAB) . . . . 103
HYDRAULIC CONTROL UNIT . . . . . . . . . . . . . . 100
TONE WHEEL (REAR AWD) . . . . . . . . . . . . . . . 111
TONE WHEEL (REAR FWD) . . . . . . . . . . . . . . . 110
WHEEL SPEED SENSOR (FRONT) . . . . . . . . . 105
WHEEL SPEED SENSOR (REAR AWD) . . . . . . 108
WHEEL SPEED SENSOR (REAR FWD) . . . . . . 106
SPECIFICATIONS
BRAKE FASTENER TORQUE
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . 112
SPEED SENSOR TONE WHEEL RUNOUT . . . . 112
WHEEL SPEED SENSOR TO TONE
WHEEL CLEARANCE . . . . . . . . . . . . . . . . . . 112
ANTILOCK BRAKES OPERATION DESCRIPTION
The purpose of an Anti l ock Brake System (ABS) i s to
prevent wheel l ock-up under braki ng condi ti ons on vi rtu-
al l y any type of road surface. Anti l ock Braki ng i s desi rabl e
because a vehi cl e whi ch i s stopped wi thout l ocki ng the
wheel s wi l l retai n di recti onal stabi l i ty and some steeri ng
capabi l i ty. Thi s al l ows the dri ver to retai n greater control
of the vehi cl e duri ng braki ng.
Thi s secti on of the servi ce manual covers the descri pti on
and on car servi ce for the I TT Teves Mark 20 ABS Brake
System and the I TT Teves Mark 20 ABS Brake System
wi th Tracti on Control . I f other servi ce i s requi red on the
non ABS rel ated components of the brake system, refer to
the appropri ate secti on i n thi s group of the servi ce manual
for the speci fi c servi ce procedure requi red.
ABS BRAKES COMPONENT ABBREVIATION LIST
I n thi s secti on of the servi ce manual , several
abbrevi ati ons are used for the components of the
Teves Mark 20 ABS Brake System and the Teves
Mark 20 ABS Brake System wi th Tracti on Control .
They are l i sted bel ow for your reference.
CABControl l er Anti l ock Brake
I CUI ntegrated Control Uni t
HCUHydraul i c Control Uni t
TCSTracti on Control
ABSAnti l ock Brake System
PSI Pounds Per Square I nch (pressure)
WSSWheel Speed Sensor
FWDFront Wheel Dri ve
AWDAl l Wheel Dri ve
DTCDi agnosti c Troubl e Code
NS BRAKES 5 - 85
ABS BRAKES OPERATION AND VEHICLE
PERFORMANCE
Thi s ABS System represents the current state-of-
the-art i n vehi cl e braki ng systems and offers the
dri ver i ncreased safety and control duri ng braki ng.
Thi s i s accompl i shed by a sophi sti cated system of
el ectri cal and hydraul i c components. As a resul t,
there are a few performance characteri sti cs that may
at fi rst seem di fferent but shoul d be consi dered nor-
mal . These characteri sti cs are di scussed bel ow.
NORMAL BRAKING SYSTEM FUNCTION
Under normal braki ng condi ti ons, the ABS System
functi ons the same as a standard brake system wi th
a di agonal l y spl i t master cyl i nder and conventi onal
vacuum assi st.
ABS SYSTEM OPERATION
I f a wheel l ocki ng tendency i s detected duri ng a
brake appl i cati on, the brake system wi l l enter the
ABS mode. Duri ng ABS braki ng, hydraul i c pressure
i n the four wheel ci rcui ts i s modul ated to prevent
any wheel from l ocki ng. Each wheel ci rcui t i s
desi gned wi th a set of el ectri c sol enoi ds to al l ow mod-
ul ati on, al though for vehi cl e stabi l i ty, both rear
wheel sol enoi ds recei ve the same el ectri cal si gnal .
Duri ng an ABS stop, the brakes hydraul i c system
i s sti l l di agonal l y spl i t. However, the brake system
pressure i s further spl i t i nto four control channel s.
Duri ng anti l ock operati on of the vehi cl es brake sys-
tem the front wheel s are control l ed i ndependentl y
and are on two separate control channel s and the
rear wheel s of the vehi cl e are control l ed together.
The system can bui l d and rel ease pressure at each
wheel , dependi ng on si gnal s generated by the wheel
speed sensors (WSS) at each wheel and recei ved at
the Control l er Anti l ock Brake (CAB).
ABS operati on i s avai l abl e at al l vehi cl e speeds
above 3 to 5 mph. Wheel l ockup may be percei ved at
the very end of an ABS stop and i s consi dered nor-
mal .
VEHICLE HANDLING PERFORMANCE DURING
ABS BRAKING
I t i s i mportant to remember that an anti l ock brake
system does not shorten a vehi cl es stoppi ng di stance
under al l dri vi ng condi ti ons, but does provi de
i mproved control of the vehi cl e whi l e stoppi ng. Vehi -
cl e stoppi ng di stance i s sti l l dependent on vehi cl e
speed, wei ght, ti res, road surfaces and other factors.
Though ABS provi des the dri ver wi th some steer-
i ng control duri ng hard braki ng, there are condi ti ons
however, where the system does not provi de any ben-
efi t. I n parti cul ar, hydropl ani ng i s sti l l possi bl e when
the ti res ri de on a fi l m of water. Thi s resul ts i n the
vehi cl es ti res l eavi ng the road surface renderi ng the
vehi cl e vi rtual l y uncontrol l abl e. I n addi ti on, extreme
steeri ng maneuvers at hi gh speed or hi gh speed cor-
neri ng beyond the l i mi ts of ti re adhesi on to the road
surface may cause vehi cl e ski ddi ng, i ndependent of
vehi cl e braki ng. For thi s reason, the ABS system i s
termed Anti l ock i nstead of Anti -Ski d.
NOISE AND BRAKE PEDAL FEEL
Duri ng ABS braki ng, some brake pedal movement
may be fel t. I n addi ti on, ABS braki ng wi l l create
ti cki ng, poppi ng and/or groani ng noi ses heard by the
dri ver. Thi s i s normal due to pressuri zed fl ui d bei ng
transferred between the master cyl i nder and the
brakes. I f ABS operati on occurs duri ng hard braki ng,
some pul sati on may be fel t i n the vehi cl e body due to
fore and aft movement of the suspensi on as brake
pressures are modul ated.
At the end of an ABS stop, ABS wi l l be turned off
when the vehi cl e i s sl owed to a speed of 34 mph.
There may be a sl i ght brake pedal drop anyti me that
the ABS i s deacti vated, such as at the end of the stop
when the vehi cl e speed i s l ess then 3 mph or duri ng
an ABS stop where ABS i s no l onger requi red. These
condi ti ons wi l l exi st when a vehi cl e i s bei ng stopped
on a road surface wi th patches of i ce, l oose gravel or
sand on i t. Al so stoppi ng a vehi cl e on a bumpy road
surface wi l l acti vate ABS because of the wheel hop
caused by the bumps.
TIRE NOISE AND MARKS
Al though the ABS system prevents compl ete wheel
l ock-up, some wheel sl i p i s desi red i n order to
achi eve opti mum braki ng performance. Wheel sl i p i s
defi ned as fol l ows, 0 percent sl i p means the wheel i s
rol l i ng freel y and 100 percent sl i p means the wheel i s
ful l y l ocked. Duri ng brake pressure modul ati on,
wheel sl i p i s al l owed to reach up to 25 to30%. Thi s
means that the wheel rol l i ng vel oci ty i s 25 to 30%
l ess than that of a free rol l i ng wheel at a gi ven vehi -
cl e speed. Thi s sl i p may resul t i n some ti re chi rpi ng,
dependi ng on the road surface. Thi s sound shoul d not
be i nterpreted as total wheel l ock-up.
Compl ete wheel l ock up normal l y l eaves bl ack ti re
marks on dry pavement. The ABS System wi l l not
l eave dark bl ack ti re marks si nce the wheel never
reaches a ful l y l ocked condi ti on. Ti re marks may
however be noti ceabl e as l i ght patched marks.
START UP CYCLE
When the i gni ti on i s turned on, a poppi ng sound
and a sl i ght brake pedal movement may be noti ced.
Addi ti onal l y, when the vehi cl e i s fi rst dri ven off a
hummi ng may be heard and/or fel t by the dri ver at
approxi matel y 20 to 40 kph (12 to 25 mph). The ABS
warni ng l amp wi l l al so be on for up to 5 seconds
after the i gni ti on i s turned on. Al l of these condi ti ons
are a normal functi on of ABS as the system i s per-
formi ng a di agnosi s check.
5 - 86 BRAKES NS
PREMATURE ABS CYCLING
NOTE: When working on a vehicle which has a
complaint of premature ABS cycling it may be nec-
essary to use a DRB Scan Tool to detect and verify
the condition.
There i s one compl ai nt cal l ed Premature ABS
Cycl i ng i n whi ch nei ther the Red Brake Warni ng
Lamp nor the Amber Anti l ock Lamp were i l l umi -
nated and no faul t codes were stored i n the CAB.
Symptoms of Premature ABS Cycl i ng, i ncl ude cl i ck-
i ng sounds from the sol enoi ds val ves, pump motor
runni ng and pul sati ons i n the brake pedal . Thi s con-
di ti on can occur at any braki ng rate of the vehi cl e
and on any type of road surface. Thi s creates an
addi ti onal condi ti on whi ch needs to be correctl y
assessed when di agnosi ng probl ems wi th the anti l ock
brake system.
The fol l owi ng condi ti ons are common causes that
need to be checked when di agnosi ng a condi ti on of
Premature ABS Cycl i ng. Damaged tone wheel s,
i ncorrect tone wheel s, damage to a wheel speed sen-
sor mounti ng boss on a steeri ng knuckl e, a l oose
wheel speed sensor mounti ng bol t, and excessi ve tone
wheel runout. Al so, an excessi vel y l arge tone wheel
to wheel speed sensor ai r gap can l ead to the condi -
ti on of Premature ABS Cycl i ng. Speci al attenti on i s
to be gi ven to these components when di agnosi ng a
vehi cl e exhi bi ti ng the condi ti on of Premature ABS
Cycl i ng. After di agnosi ng the defecti ve component,
repai r or repl ace as requi red.
When the component repai r or repl acement i s com-
pl eted, test dri ve the vehi cl e to veri fy the condi ti on of
Premature ABS Cycl i ng has been corrected.
ABS BRAKE SYSTEM COMPONENTS
The fol l owi ng i s a detai l ed descri pti on of the Teves
Mark 20 ABS brake system components. For i nfor-
mati on on servi ci ng the base brake system compo-
nents, see the base Brake System secti on of thi s
Servi ce Manual .
ABS MASTER CYLINDER AND POWER BRAKE
BOOSTER
A vehicle equipped with Teves Mark 20 ABS
without optional traction control uses the same
type of a master cylinder and power brake
booster (Fig. 1) as a vehicle not equipped with
antilock brakes.
A vehicle equipped with Teves Mark 20 ABS
with Traction control uses a unique center port
master cylinder. If the master cylinder is
replaced on a vehicle equipped with traction
control be sure the right type of master cylin-
der is installed.
A vehicle equipped with four wheel disc
brakes (AWD applications) also have a unique
master cylinder. The master cylinder used on
these vehicles have a piston bore diameter
which is larger then the master cylinder used
on the other brake applications.
The pri mary and secondary outl et ports on the
master cyl i nder go di rectl y to the hydraul i c control
uni t HCU.
Reference the appropri ate secti on of thi s servi ce
manual for further i nformati on on the i ndi vi dual
components.
INTEGRATED CONTROL UNIT (ICU)
The hydraul i c control uni t (HCU) (Fi g. 2) used
wi th the Teves Mark 20 ABS i s di fferent from the
HCU used on previ ous Chrysl er products wi th ABS.
The HCU used on thi s ABS system i s part of the
i ntegrated contol uni t (I CU). The HCU i s part of
what i s referred to as the I CU because the HCU and
the control l er anti l ock brakes (CAB) are combi ned
(i ntegrated) i nto one uni t. Thi s di ffers from previ ous
Chrysl er products wi th ABS, where the HCU and the
CAB were separate components l ocated i n di fferent
areas of the vehi cl e.
Teves Mark 20 ABS uses two di fferent HCUs and
CABs dependi ng on the type of ABS system the vehi -
cl e i s equi pped wi th. There i s a uni que HCU and
CAB for a vehi cl e equi pped wi th just ABS and a
uni que HCU and CAB for a vehi cl e equi pped wi th
ABS and tracti on control .
NOTE: The HCU and CAB used on a vehicle that is
equipped with only ABS and on a vehicle that is
equipped with ABS and traction control are differ-
ent. The HCU on a vehicle equipped with ABS and
traction control has a valve block housing (Fig. 2)
that is approximately 1 inch longer on the low pres-
sure fluid accumulators side than a HCU for a vehi-
cle that is equipped with only ABS.
Fig. 1 Master Cylinder And Vacuum Booster
NS BRAKES 5 - 87
The I CU i s l ocated on the dri vers si de of the vehi -
cl e, and i s mounted to the front suspensi on cradl e
(Fi g. 3). The ABS only I CU contai ns the fol l owi ng
components for control l i ng the brake system hydrau-
l i c pressure duri ng ABS braki ng: The CAB, ei ght
val ve sol enoi ds, (four i nl et val ves and four outl et
val ves) fl ui d accumul ators a pump, and an el ectri c
motor. The ABS with traction control I CU con-
tai ns the fol l owi ng components for control l i ng the
brake system hydraul i c pressure duri ng ABS braki ng
and tracti on control operati on: The CAB, four sol e-
noi d control l ed i nl et val ves, four sol enoi d control l ed
outl et val ves, two hydraul i c shuttl e val ves, two ASR
val ves, fl ui d accumul ators a pump and an el ectri c
motor. Al so attached to the hydraul i c control uni t are
the master cyl i nder pri mary and secondary brake
tubes and the brake tubes goi ng to each wheel of the
vehi cl e. (Fi g. 3).
CAUTION: No components of the ICU are service-
able. If any component that makes up the ICU is
diagnosed as not functioning properly it MUST be
replaced. The replaceable components of the ICU,
are the HCU and the CAB (Fig. 2) and (Fig. 3). The
mounting bracket is also replaceable as a separate
component of the ICU. The remaining components
of the ICU are not serviceable items. No attempt
should ever be made to remove or service any indi-
vidual components of the HCU. This is due to the
concern of contamination entering the HCU while
performing a service procedure. Also no attempt
should ever be made to remove or service any indi-
vidual components of the CAB.
CAUTION: At no time when servicing the ICU
should a 12 volt power source be applied to any
electrical connector of the HCU or the CAB.
INLET VALVES AND SOLENOIDS
There are four i nl et sol enoi ds, one for each wheel .
I n the rel eased posi ti on they provi de a fl ui d path
from the master cyl i nder to the wheel brakes of the
vehi cl e. When the ABS cycl e has been compl eted the
i nl et sol enoi ds wi l l return to thei r rel eased (open)
posi ti on.
OUTLET VALVES AND SOLENOIDS
There are four outl et sol enoi ds, one for each wheel .
I n the rel eased posi ti on they are cl osed to al l ow for
normal braki ng. I n the actuated (open) posi ti on, they
provi de a fl ui d path from the wheel brakes of the
vehi cl e to the hydraul i c control uni t HCU accumul a-
tors and pump motor. The outl et sol enoi ds are spri ng
l oaded i n the rel eased (cl osed) posi ti on duri ng normal
braki ng.
ASR VALVE (ABS WITH TRACTION CONTROL
ONLY)
On vehi cl es equi pped wi th ABS havi ng tracti on
control , there are two speci al ASR val ves l ocated i n
the HCU porti on of the I CU. The ASR val ves are a
normal l y open type val ve and are sol enoi d actuated.
The speci al ASR val ves are used to i sol ate the rear
(non-dri ven) wheel s of the vehi cl e from the hydraul i c
pressure that the HCU pump motor i s sendi ng to the
front (dri ven) wheel s, when the tracti on control sys-
tem i s i n operati on. The rear brakes need to be i so-
l ated from the master cyl i nder when tracti on control
i s i n operati on so that the HCU can bui l d the
requi red hydraul i c pressure to the front brakes.
HCU BRAKE FLUID ACCUMULATORS AND NOISE
DAMPING CHAMBER
There are two brake fl ui d accumul ators i n the
HCU. There i s one brake fl ui d accuml ator for the pri -
mary and secondary hydraul i c ci rcui ts. The brake
Fig. 2 Teves Mark 20 ICU Fig. 3 ICU Mounting Location
5 - 88 BRAKES NS
fl ui d accumul ators temporari l y store brake fl ui d that
i s decayed from the wheel brakes duri ng an ABS
cycl e. Thi s stored brake fl ui d i s then used by the
pump i n the HCU to provi de bui l d pressure for the
brake hydraul i c system.
Addi ti onal l y on vehi cl es that are equi pped wi th
onl y ABS (non-tracti on control vehi cl es) there i s a
mi ni brake fl ui d accumul ator on the secondary
hydraul i c ci rcui t whi ch protects the master cyl i nders
seal s duri ng an ABS stop. There i s al so a noi se
dampi ng chamber on the pri mary hydraul i c ci rcui t.
On ABS equi pped vehi cl es wi th tracti on control , i n
addi ti on to the brake fl ui d accumul ators there are
al so two noi se dampi ng chambers i n the HCU.
HCU PUMP/MOTOR
The HCU (Fi g. 4) contai ns 2 pump assembl i es, one
for the pri mary and one for the secondary hydraul i c
ci rcui t of the brake system. Both pumps are dri ven
by a common el ectri c motor (Fi g. 4) whi ch i s part of
the HCU. The pumps draw brake fl ui d from the fl ui d
accumul ators to suppl y bui l d pressure to the brakes
duri ng an ABS stop. The pump motor runs duri ng
the dri ve-off cycl e as a check and duri ng an ABS stop
and i s control l ed by the CAB. The Pump/Motor
Assembl y i s not a servi ceabl e i tem. I f the pump/mo-
tor requi res repl acement the compl ete HCU (Fi g. 4)
(mi nus the CAB) must be repl aced.
ABS FUSES
The fuse for the ABS pump motor and the ABS system
are l ocated i n the power di stri buti on center (PDC) (Fi g. 5).
The PDC i s l ocated on the dri vers si de of the engi ne com-
partment forward of the strut tower. The fuse for the ABS
warni ng l amp i n the i nstrument panel message center i s
l ocated i n the juncti on bl ock.
On vehi cl es equi pped wi th tracti on control , the
fuse for the tracti on control swi tch i s al so l ocated i n
the juncti on bl ock.
The juncti on bl ock i s l ocated on the l eft hand front
cowl panel on the vehi cl e.
ABS RELAYS
On the Teves Mark 20 Anti l ock Brake System both
the pump motor rel ay and the system rel ay are
l ocated i n the CAB. I f ei ther of the rel ays i s di ag-
nosed as not functi oni ng properl y the CAB wi l l need
to be repl aced. Refer to Control l er Anti l ock Brakes i n
the Removal And I nstal l ati on Secti on i n thi s group of
the servi ce manual for the procedure.
One assembl y contai ni ng two proporti oni ng val ves
are used i n the system, one for each rear brake
hydraul i c ci rcui t. The proporti oni ng val ve i s l ocated
on the frame rai l next to the fuel tank, forward of the
ri ght rear shock absorber (Fi g. 6). Be sure repl ace-
ment proporti oni ng val ve assembl i es have the same
spl i t poi nt and sl ope as the proporti oni ng val ve bei ng
repl aced.
WHEEL SPEED SENSORS
One Wheel Speed Sensor WSS i s l ocated at each
front and rear wheel of the vehi cl e (Fi g. 7), (Fi g. 8)
and (Fi g. 9). The wheel speed sensor sends a smal l
AC si gnal to the CAB. Thi s si gnal i s generated by
magneti c i nducti on created when a toothed sensor
ri ng (tone wheel ) (Fi g. 7), (Fi g. 8) and (Fi g. 9) passes
the stati onary magneti c wheel speed sensor. The
CAB converts the AC si gnal generated at each wheel
i nto a di gi tal si gnal . I f a wheel l ocki ng tendency i s
detected by the CAB, i t wi l l then modul ate hydraul i c
pressure vi a the HCU to prevent the wheel (s) from
l ocki ng.
Fig. 4 Teves Mark 20 HCU Pump/Motor
Fig. 5 Fuse Locations In Power Distribution Center
NS BRAKES 5 - 89
The front wheel speed sensor i s attached to a boss
i n the steeri ng knuckl e (Fi g. 7). The front tone wheel
(Fi g. 7) i s part of the dri veshafts outboard constant
vel oci ty joi nt. The rear wheel speed sensor i s
mounted through the rear axl e, rear brake support
pl ate and di rectl y to the rear beari ng (Fi g. 8) (Fi g. 9).
The rear tone wheel on a front wheel dri ve vehi cl e i s
an i ntegral part of the rear wheel hub/beari ng
assembl y. I f damaged though, the rear tone wheel on
a front wheel dri ve vehi cl e can be repl aced as a i ndi -
vi dual component of the rear hub/beari ng assembl y.
Refer to Rear Tone Wheel i n the Remove And I nstal l
Secti on i n thi s group of the servi ce manual for the
requi red procedure. The wheel speed sensor ai r gap
i s NOT adjustabl e.
The rear tone wheel on a al l wheel dri ve vehi cl e, i s
part of the outboard constant vel oci ty joi nt on the
rear dri veshaft (Fi g. 9).
The four wheel speed sensors are al l servi ced i ndi -
vi dual l y, but the front tone wheel on al l vehi cl es and
the rear tone wheel on al l wheel dri ve vehi cl es are
servi ced as part of the front or rear dri veshaft out-
board constant vel oci ty joi nt (Fi g. 7) and (Fi g. 9).
Correct ABS system operati on i s dependent on
accurate wheel speed si gnal s. The vehi cl es wheel s
and ti res must al l be the same si ze and type to gen-
erate accurate si gnal s. Vari ati ons i n wheel and ti re
si ze can produce i naccurate wheel speed si gnal s,
whi ch can cause fal se ABS cycl es to occur.
CONTROLLER ANTILOCK BRAKES (CAB)
The Control l er Anti l ock Brakes (CAB) i s a mi cro-
processor based devi ce whi ch moni tors the ABS sys-
tem duri ng normal braki ng and control s i t when the
vehi cl e i s i n an ABS stop. The CAB i s mounted to the
bottom of the HCU (Fi g. 10). The CAB uses a 25 way
el ectri cal connector on the vehi cl e wi ri ng harness.
The power source for the CAB i s through the i gni ti on
swi tch i n the Run or On posi ti on. THE (CAB) IS ON
THE CCD BUS
Fig. 6 Proportioning Valve Mounting Location
Fig. 7 Front Wheel Speed Sensor
Fig. 8 Rear Wheel Speed Sensor (FWD)
Fig. 9 Rear Wheel Speed Sensor (AWD)
5 - 90 BRAKES NS
The pri mary functi ons of the (CAB) are:
(1) Detect wheel l ocki ng or wheel sl i ppi ng tenden-
ci es by moni tori ng the speed of al l four wheel s of the
vehi cl e.
(2) I l l umi nate the TRAC l amp i n the message cen-
ter on the i nstrument panel when a tracti on control
event i s occurri ng.
(3) Control fl ui d modul ati on to the wheel brakes
whi l e the system i s i n an ABS mode or the tracti on
control system i s acti vated.
(4) Moni tor the system for proper operati on.
(5) Provi de communi cati on to the DRB Scan Tool
whi l e i n di agnosti c mode.
(6) Store di agnosti c i nformati on.
(7) The CAB continuously communicates with
the body controller by sending out a message to
the body controller on the CCD Bus. This mes-
sage is used for illumination of the yellow
antilock warning lamp. This is used if the ABS
controller communication is lost in the hard
wire between the body controller and the yel-
low antilock warning lamp. If the body control-
ler does not receive this message fromthe CAB,
the body controller will illuminate the antilock
yellow warning lamp.
The CAB conti nuousl y moni tors the speed of each
wheel through the si gnal s generated by the wheel
speed sensors to determi ne i f any wheel i s begi nni ng
to l ock. When a wheel l ocki ng tendency i s detected,
the CAB commands the CAB command coi l s to actu-
ate. The CAB command coi l s then open and cl ose the
val ves i n the HCU whi ch modul ate brake fl ui d pres-
sure i n some or al l of the hydraul i c ci rcui ts. The CAB
conti nues to control pressure i n i ndi vi dual hydraul i c
ci rcui ts unti l a l ocki ng tendency i s no l onger present.
The ABS system i s constantl y moni tored by the
CAB for proper operati on. I f the CAB detects a faul t,
i t wi l l turn on the Amber ABS Warni ng Lamp and
di sabl e the ABS braki ng system. The normal base
braki ng system wi l l remai n operati onal .
The CAB contai ns a sel f-di agnosti c program whi ch
wi l l turn on the Amber ABS Warni ng Lamp when a
ABS system faul t i s detected. Faul ts are then stored
i n a di agnosti c program memory. There are mul ti pl e
faul t messages whi ch may be stored i n the CAB and
di spl ayed through the DRB Scan Tool . These faul t
messages wi l l remai n i n the CAB memory even after
the i gni ti on has been turned off. The faul t messages
can be read and or cl eared from the CAB memory by
a techni ci an usi ng the DRB Scan Tool . The faul t
occurrence and the faul t code wi l l al so be automati -
cal l y cl eared from the CAB memory after the i denti -
cal faul t has not been seen duri ng the next 3500
mi l es of vehi cl e operati on. Mi l eage though of the l ast
faul t occurrence wi l l not be automati cal l y cl eared.
CONTROLLER ANTILOCK BRAKE INPUTS
Four wheel speed sensors.
Stop l amp swi tch.
I gni ti on swi tch.
System rel ay vol tage.
Ground.
Tracti on Control Swi tch (I f Equi pped).
Di agnosti cs Communi cati ons (CCD)
CONTROLLER ANTILOCK BRAKE OUTPUTS
C2D Communi cati on To Body Control l er And
I nstrument Cl uster
ABS warni ng l amp actuati on.
Tracti on Control Li ght (I f Equi pped).
Di agnosti c communi cati on. (CCD)
ABS WARNING LAMP (YELLOW)
The ABS system uses a yel l ow col ored ABS Warn-
i ng Lamp. The ABS warni ng l amp i s l ocated on the
ri ght si de of the message center l ocated at the top of
the i nstrument panel . The purpose of the warni ng
l amp i s di scussed i n detai l bel ow.
The ABS warni ng l amp wi l l turn on when the CAB
detects a condi ti on whi ch resul ts i n a shutdown of
ABS functi on or when the body control l er does not
recei ve C2D messages from the CAB. When the i gni -
ti on key i s turned to the on posi ti on, the ABS Warn-
i ng Lamp i s on unti l the CAB compl etes i ts sel f tests
and turns the l amp off (approxi matel y 4 seconds
after the i gni ti on swi tch i s turned on). Under most
condi ti ons, when the ABS warni ng l amp i s on, onl y
the ABS functi on of the brake system i s affected. The
standard brake system and the abi l i ty to stop the car
wi l l not be affected when onl y the ABS warni ng l amp
i s on.
The ABS warni ng l amp i s control l ed by the CAB
and the body control l er through a di ode l ocated i n
the wi ri ng harness juncti on bl ock. The juncti on bl ock
i s l ocated under the i nstrument panel to the l eft of
Fig. 10 Controller Antilock Brake (CAB)
NS BRAKES 5 - 91
the steeri ng col umn. The CAB and the body control -
l er, control s the yel l ow ABS warni ng l amp by di rectl y
groundi ng the ci rcui t.
HYDRAULIC CIRCUITS AND VALVE OPERATION
Through the fol l owi ng operati on descri pti ons the
functi on of the vari ous hydraul i c control val ves i n the
ABS wi l l be descri bed. The fl ui d control val ves men-
ti oned bel ow, control the fl ow of pressuri zed brake
fl ui d to the wheel brakes duri ng the di fferent modes
of ABS braki ng.
For expl anati on purposes, al l wheel speed sensors
except the ri ght front are sendi ng the same wheel
speed i nformati on. The fol l owi ng di agrams show onl y
the ri ght front wheel i n a anti l ock braki ng condi ti on.
NORMAL BRAKING HYDRAULIC CIRCUIT AND
SOLENOID VALVE FUNCTION
Thi s condi ti on i s the normal operati on of the vehi -
cl es base brake hydraul i c system. The hydraul i c sys-
tem ci rcui t di agram (Fi g. 11) shows a si tuati on where
no wheel spi n or sl i p i s occurri ng rel ati ve to the
speed of the vehi cl e. The dri ver i s appl yi ng the brake
pedal to bui l d pressure i n the brake hydraul i c system
to appl y the brakes and stop the vehi cl e.
TEVES MARK 20 ABS CIRCUIT AND
SOLENOID VALVE FUNCTION
Thi s hydraul i c ci rcui t di agram (Fi g. 12) shows the
vehi cl e i n the ABS braki ng mode. Thi s hydraul i c ci r-
cui t (Fi g. 12) shows a si tuati on where one wheel i s
sl i ppi ng because the dri ver i s attempti ng to stop the
vehi cl e at a faster rate than the surface the vehi cl es
ti res are on wi l l al l ow. The normal l y open and nor-
mal l y cl osed val ves modul ate the brake hydraul i c
pressure as requi red. The pump/motor i s swi tched on
so that the brake fl ui d from the l ow pressure accu-
mul ators i s returned to the master cyl i nder ci rcui ts.
The brake fl ui d wi l l then be routed to ei ther the mas-
ter cyl i nder or the wheel brake dependi ng on the
posi ti on of the normal l y open val ve.
TEVES MARK 20 SECONDARY ABS CIRCUIT
AND SOLENOID VALVE FUNCTION
Thi s hydraul i c ci rcui t di agram (Fi g. 13) shows the
vehi cl e i n the ABS braki ng mode. Thi s hydraul i c ci r-
cui t (Fi g. 13) shows a si tuati on where one wheel i s
sl i ppi ng because the dri ver i s attempti ng to stop the
vehi cl e at a faster rate than the surface the vehi cl es
ti res are on wi l l al l ow. The normal l y open and nor-
mal l y cl osed val ves modul ate the brake hydraul i c
pressure as requi red. The pump/motor i s swi tched on
so that the brake fl ui d from the l ow pressure accu-
Fig. 11 Normal Braking Hydraulic Circuit
5 - 92 BRAKES NS
mul ators i s returned to the master cyl i nder ci rcui ts.
The brake fl ui d wi l l then be routed to ei ther the mas-
ter cyl i nder or the wheel brake dependi ng on the
posi ti on of the normal l y open val ve. A vol ume of 1.2
ccs of brake fl ui d i s taken i n by the l i p seal saver
(Fi g. 13) to protect the l i p seal s on the pi ston of the
master cyl i nder.
TEVES MARK 20 ABS WITH TRACTION
CONTROL NORMAL BRAKING HYDRAULIC
CIRCUIT SOLENOID AND SHUTTLE VALVE
FUNCTION
Thi s condi ti on i s the normal operati on of the vehi -
cl es base brake hydraul i c system when the vehi cl e i s
equi pped wi th ABS and tracti on control . The hydrau-
l i c system ci rcui t di agram (Fi g. 14) shows a si tuati on
where no wheel spi n or sl i p i s occurri ng rel ati ve to
the speed of the vehi cl e. The dri ver i s appl yi ng the
brake pedal to bui l d pressure i n the brake hydraul i c
system to appl y the brakes and stop the vehi cl e. The
hydraul i c shuttl e val ve (Fi g. 14) cl oses wi th every
brake pedal appl i cati on so pressure i s not created at
the i nl et to the pump.
CONTROL ABS BRAKING HYDRAULIC
FUNCTION
Thi s hydraul i c ci rcui t di agram (Fi g. 15) shows a
vehi cl e equi pped wi th ABS and tracti on control i n
the ABS braki ng mode. Thi s hydraul i c ci rcui t (Fi g.
15) shows a si tuati on where one wheel i s sl i ppi ng
because the dri ver i s attempti ng to stop the vehi cl e
at a faster rate than the surface the vehi cl es ti res
are on wi l l al l ow. The hydraul i c shuttl e val ve (Fi g.
15) cl oses upon brake appl i cati on so that the pump
can not suck brake fl ui d from the master cyl i nder.
The normal l y open and normal l y cl osed val ves mod-
ul ate the brake hydraul i c pressure as requi red. The
pump/motor i s swi tched on so that the brake fl ui d
from the l ow pressure accumul ators i s returned to
the master cyl i nder ci rcui ts. The brake fl ui d wi l l
then be routed to ei ther the master cyl i nder or the
wheel brake dependi ng on the posi ti on of the nor-
mal l y open val ve.
Fig. 12 ABS Mode Hydraulic Circuit
NS BRAKES 5 - 93
Fig. 13 ABS Mode Secondary Hydraulic Circuit
Fig. 14 ABS With Traction Control Normal Braking Hydraulic Circuit
5 - 94 BRAKES NS
CONTROL TRACTION CONTROL HYDRAULIC
FUNCTION
Thi s hydraul i c ci rcui t di agram (Fi g. 16) shows a
vehi cl e equi pped wi th ABS and tracti on control i n
the tracti on control mode. The hydraul i c ci rcui t (Fi g.
16) shows a si tuati on where a dri ven wheel i s spi n-
ni ng and brake pressure i s requi red to reduce i ts
speed. The normal l y open ASR val ve (Fi g. 16) i s ener-
gi zed to i sol ate the brake fl ui d bei ng pumped from
the master cyl i nder and to i sol ate the dri ven wheel .
Al so, the normal l y open ASR val ve bypasses the
pump output back to the master cyl i nder at a fi xed
pressure setti ng. The normal l y open and normal l y
cl osed val ves (Fi g. 16) modul ate the brake pressure
as requi red to the spi nni ng wheel .
ABS GENERAL DIAGNOSTICS INFORMATION
Thi s secti on contai ns the i nformati on necessary to
di agnose the I TT Teves Mark 20 ABS Brake System.
Speci fi cal l y, thi s secti on shoul d be used to hel p di ag-
nose condi ti ons whi ch resul t i n any of the fol l owi ng:
(1) ABS Warni ng Lamp turned on.
(2) Brakes Lock-up on hard appl i cati on
Di agnosi s of base brake condi ti ons whi ch are obvi -
ousl y mechani cal i n nature shoul d be di rected to
Group 5 Brakes i n thi s servi ce manual . Thi s i ncl udes
brake noi se, brake pul sati on, l ack of power assi st,
parki ng brake, Red BRAKE Warni ng Lamp l i ghti ng,
or vehi cl e vi brati on duri ng normal braki ng.
Many condi ti ons that generate customer com-
pl ai nts may be normal operati ng condi ti ons, but are
judged to be a probl em due to not bei ng fami l i ar wi th
the ABS system. These condi ti ons can be recogni zed
wi thout performi ng extensi ve di agnosti c work, gi ven
adequate understandi ng of the operati ng pri nci pl es
and performance characteri sti cs of the ABS. See the
ABS System Operati on Secti on i n thi s group of the
servi ce manual to fami l i ari ze yoursel f wi th the oper-
ati ng pri nci pl es of the ABS system.
ABS WIRING DIAGRAM INFORMATION
Duri ng the di agnosi s of the anti l ock brake system
i t may become necessary to reference the wi ri ng di a-
grams coveri ng the anti l ock brake system and i ts
components. For wi ri ng di agrams refer to Anti l ock
Brakes i n Group 8W of thi s servi ce manual . Thi s
group wi l l provi de you wi th the wi ri ng di agrams and
the ci rcui t descri pti on and operati on i nformati on cov-
eri ng the anti l ock brake system.
Fig. 15 ABS With Traction Control ABS Braking Hydraulic Circuit
NS BRAKES 5 - 95
ABS DIAGNOSTICS MANUAL
Detai l ed procedures for di agnosi ng speci fi c ABS
condi ti ons are covered i n the di agnosti cs manual cov-
eri ng the I TT Teves Mark 20 ABS system. The fol -
l owi ng i nformati on i s presented to gi ve the
techni ci an a general background on the di agnosti c
capabi l i ti es of the I TT Teves Mark 20 ABS system.
Pl ease refer to the above menti oned manual for any
further el ectroni c di agnosti cs and servi ce procedures
that are requi red.
DRB DIAGNOSTIC SCAN TOOL USAGE
The di agnosti cs of the I TT Teves Mark 20 ABS sys-
tem i s performed usi ng the DRB scan tool . Refer to
the di agnosti cs manual coveri ng the I TT Teves Mark
20 ABS system for the requi red di agnosti cs and test-
i ng procedures and the DRB operators manual for i ts
proper operati onal i nformati on.
ABS BRAKE DIAGNOSTIC TOOL CONNECTOR
On thi s vehi cl e, the di agnosti c connector used for
the di agnosi s of the I TT Teves Mark 20 ABS system
i s l ocated under the l ower steeri ng col umn cover, to
the l eft si de of the steeri ng col umn, just bel ow the
hood rel ease l ever (Fi g. 17). The I TT Teves Mark 20
ABS system uses the I SO 9141-K connector whi ch i s
shared by other vehi cl e di agnosti c systems such as
the powertrai n control modul e and ai r bag el ectroni c
control modul e.
ABS SYSTEM SELF DIAGNOSTICS
The I TT Teves Mark 20 ABS system i s equi pped
wi th a sel f di agnosti c capabi l i ty whi ch may be used
to assi st i n the i sol ati on of ABS faul ts. The features
of the sel f di agnosti cs system are descri bed bel ow.
Fig. 16 Traction Control Hydraulic Circuit
Fig. 17 Diagnostic Scan Tool Data Link Connector
5 - 96 BRAKES NS
START-UP CYCLE
The sel f di agnosti c ABS start up cycl e begi ns when
the i gni ti on swi tch i s turned to the on posi ti on. El ec-
tri cal checks are compl eted on ABS components, such
as the Control l er, sol enoi d conti nui ty, and the system
rel ay operati on. Duri ng thi s check the Amber ABS
Warni ng Li ght i s turned on for approxi matel y 4 sec-
onds and the brake pedal may emi t a poppi ng sound
and move sl i ghtl y when the sol enoi d val ves are
checked.
DRIVE-OFF CYCLE
Further Functi onal testi ng i s accompl i shed once
the vehi cl e i s set i n moti on and reaches a speed of
about 20 kph (12 mph.). Thi s cycl e i s performed onl y
once after each i gni ti on on/off cycl e.
The pump/motor i s acti vated bri efl y to veri fy
functi on. When the pump/motor i s acti vated a whi rl -
i ng or buzzi ng sound may be heard by the dri ver,
whi ch i s normal when the pump/motor i s runni ng.
The wheel speed sensor output i s veri fi ed to be
wi thi n the correct operati ng range.
ONGOING TESTS
Other tests are performed on a conti nuous basi s.
These i ncl ude checks for sol enoi d conti nui ty, wheel
speed sensor conti nui ty and wheel speed sensor out-
put.
ABS DIAGNOSTIC TROUBLE CODES
Di agnosti c troubl e codes (DTC) are kept i n the con-
trol l ers memory unti l ei ther erased by the techni ci an
usi ng the DRB or erased automati cal l y after 3500
mi l es. DTCs are retai ned by the control l er even i f
the i gni ti on i s turned off or the battery i s di scon-
nected. More than one DTC can be stored at a ti me.
The mi l eage of the most recent occurrence, number of
occurrences and the DTC that was stored i s al so di s-
pl ayed. Most functi ons of the CAB and the ABS sys-
tem can be accessed by the techni ci an for testi ng and
di agnosti c purposes by usi ng the DRB.
LATCHING VERSUS NON-LATCHING
DIAGNOSTIC TROUBLE CODES
Some DTCs detected by the CAB are l atchi ng; the
DTC i s l atched and ABS braki ng i s di sabl ed unti l the
i gni ti on swi tch i s reset. Thus ABS braki ng i s non
operati onal even i f the ori gi nal DTC has di sappeared.
Other DTCs are non-l atchi ng; any warni ng l i ghts
that are turned on, are onl y turned on as l ong as the
DTC condi ti on exi sts. As soon as the condi ti on goes
away, the ABS Warni ng Li ght i s turned off, al though
a DTC wi l l be set i n most cases.
INTERMITTENT DIAGNOSTIC TROUBLE CODES
As wi th vi rtual l y any el ectroni c system, i ntermi t-
tent el ectri cal probl ems i n the ABS system may be
di ffi cul t to accuratel y di agnose.
Most i ntermi ttent el ectri cal probl ems are caused
by faul ty el ectri cal connecti ons or wi ri ng. When an
i ntermi ttent faul t i s encountered, check suspect ci r-
cui ts for:
A vi sual i nspecti on for l oose, di sconnected, or mi s-
routed wi res shoul d be done before attempti ng to
di agnose or servi ce the I TT Teves Mark 20 anti l ock
brake system. A vi sual i nspecti on wi l l el i mi nate
unnecessary testi ng and di agnosti cs ti me. A thorough
vi sual i nspecti on wi l l i ncl ude the fol l owi ng compo-
nents and areas of the vehi cl e.
(1) I nspect fuses i n the power di stri buti on center
(PDC) and the wi ri ng juncti on bl ock. Veri fy that al l
fuses are ful l y i nserted i nto the PDC and wri ng junc-
ti on bl ock. A l abel on the undersi de of the PDC cover
i denti fi es the l ocati ons of the ABS fuses i n the PDC.
(2) I nspect the 25-way el ectri cal connector at the
CAB for damage, spread or backed-out wi ri ng termi -
nal s. Veri fy that the 25-way connector i s ful l y
i nserted i n the socket on the CAB. Be sure that wi res
are not stretched ti ght or pul l ed out of the connector.
(3) Veri fy that al l the wheel speed sensor connec-
ti ons are secure.
(4) Poor mati ng of connector hal ves or termi nal s
not ful l y seated i n the connector body.
(5) I mproperl y formed or damaged termi nal s. Al l
connector termi nal s i n a suspect ci rcui t shoul d be
careful l y reformed to i ncrease contact tensi on.
(6) Poor termi nal to wi re connecti on. Thi s requi res
removi ng the termi nal from the connector body to
i nspect.
(7) Pi n presence i n the connector assembl y
(8) Proper ground connecti ons. Check al l ground
connecti ons for si gns of corrosi on, ti ght fasteners, or
other potenti al defects. Refer to wi ri ng di agram man-
ual for ground l ocati ons.
(9) Probl ems wi th mai n power sources of the vehi -
cl e. I nspect battery, generator, i gni ti on ci rcui ts and
other rel ated rel ays and fuses.
(10) I f a vi sual check does not fi nd the cause of the
probl em, operate the car i n an attempt to dupl i cate
the condi ti on and record the troubl e code.
(11) Most fai l ures of the ABS system wi l l di sabl e
ABS functi on for the enti re i gni ti on cycl e even i f the
faul t cl ears before key-off. There are some fai l ure
condi ti ons, however, whi ch wi l l al l ow ABS operati on
to resume duri ng the i gni ti on cycl e i n whi ch a fai l ure
occurred i f the fai l ure condi ti ons are no l onger
present. The fol l owi ng condi ti ons may resul t i n i nter-
mi ttent i l l umi nati on of the ABS Warni ng Lamp. Al l
other fai l ures wi l l cause the l amp to remai n on unti l
the i gni ti on swi tch i s turned off. Ci rcui ts i nvol vi ng
NS BRAKES 5 - 97
these i nputs to the CAB shoul d be i nvesti gated i f a
compl ai nt of i ntermi ttent warni ng system operati on
i s encountered.
(12) Low system vol tage. I f Low System Vol tage i s
detected by the CAB, the CAB wi l l turn on the ABS
Warni ng Lamp unti l normal system vol tage i s
achi eved. Once normal vol tage i s seen at the CAB,
normal operati on resumes.
(13) Hi gh system vol tage. I f hi gh system vol tage i s
detected by the CAB, the CAB wi l l turn on the
Amber ABS Warni ng Lamp unti l normal system vol t-
age i s achi eved. Once normal vol tage i s agai n
detected by the CAB, normal ABS operati on wi l l be
resumed at the next key on cycl e.
(14) Addi ti onal l y, any condi ti on whi ch resul ts i n
i nterrupti on of el ectri cal current to the CAB or mod-
ul ator assembl y may cause the ABS Warni ng Lamp
to turn on i ntermi ttentl y.
(15) The body control l er can turn on the (yel l ow)
ABS warni ng l amp i f CCD communi cati on between
the body control l er and the CAB i s i nterupted.
TONEWHEEL INSPECTION
CAUTION: The tone wheels used on this vehicle
equipped with the Teves Mark 20 Antilock Brake
System are different then those used on past mod-
els of this vehicle equipped with antilock brakes.
Reduced braking performance will result if this part
is used on earlier model vehicles and an accident
could result. Do not use on pre-1998 model year
vehicles.
Careful l y i nspect tonewheel at the suspected faul ty
wheel speed sensor for mi ssi ng, chi pped or broken
teeth, thi s can cause errati c speed sensor si gnal s.
Tonewheel s shoul d show no evi dence of contact
wi th the wheel speed sensors. I f contact was made,
determi ne cause and correct before repl aci ng the
wheel speed sensor.
Excessi ve runout of the tonewheel can cause
errati c wheel speed sensor si gnal s. Refer to Tone-
wheel Runout i n the Speci fi cati on Secti on i n thi s sec-
ti on of the servi ce manual for the tonewheel runout
speci fi cati on. Repl ace dri ve shaft assembl y or rear
hub/beari ng assembl y i f tonewheel runout exceeds
the speci fi cati on.
I nspect tonewheel s for l ooseness on thei r mounti ng
surfaces. Tonewheel s are pressed onto thei r mounti ng
surfaces and shoul d not rotate i ndependentl y from
the mounti ng surface.
Check the wheel speed sensor head al i gnment to
the tone wheel . Al so check the gap between the speed
sensor head and the tone wheel to ensure i t i s at
speci fi cati on. Refer to Wheel Speed Sensor Cl earance
i n the Speci fi cati on Secti on i n thi s secti on of the ser-
vi ce manual .
PROPORTIONING VALVE
CAUTION: Proportioning valves (Fig. 18) should
never be disassembled.
I f premature rear wheel ski d occurs on hard brake
appl i cati on, i t coul d be an i ndi cati on that a mal func-
ti on has occurred wi th one of the proporti oni ng
val ves.
I f a mal functi oni ng proporti oni ng val ve i s sus-
pected on a vehi cl e, refer to Proporti oni ng Val ve Test
i n the Proporti oni ng Val ves Secti on i n thi s group of
the servi ce manual for the requi red test procedure.
BRAKE FLUID CONTAMINATION
I ndi cati ons of fl ui d contami nati on are swol l en or
deteri orated rubber parts.
Swol l en rubber parts i ndi cate the presence of
petrol eum i n the brake fl ui d.
To test for contami nati on, put a smal l amount of
drai ned brake fl ui d i n cl ear gl ass jar. I f fl ui d sepa-
rates i nto l ayers, there i s mi neral oi l or other fl ui d
contami nati on of the brake fl ui d.
I f brake fl ui d i s contami nated, drai n and thor-
oughl y fl ush system. Repl ace master cyl i nder, propor-
ti oni ng val ve, cal i per seal s, wheel cyl i nder seal s,
Anti l ock Brakes hydraul i c uni t and al l hydraul i c
fl ui d hoses.
TEST DRIVING ABS COMPLAINT VEHICLE
Most ABS compl ai nts wi l l requi re a test dri ve as a
part of the di agnosti c procedure. The purpose of the
test dri ve i s to dupl i cate the condi ti on.
NOTE: Remember conditions that result in the
turning on of the Red BRAKE Warning Lamp may
indicate reduced braking ability. The following pro-
cedure should be used to test drive an ABS com-
plaint vehicle.
Fig. 18 Brake Proportioning Valve Identification
5 - 98 BRAKES NS
Before test dri vi ng a brake compl ai nt vehi cl e, note
whether the Red or Amber Brake Warni ng Lamp i s
turned on. I f i t i s the Red Brake Warni ng Lamp,
refer to the hydraul i c system secti on i n the brake
group of thi s manual . I f the ABS Warni ng l amp
was/i s on, test dri ve the vehi cl e as descri bed bel ow, to
veri fy the compl ai nt. Whi l e the ABS Warni ng Lamp
i s on, the ABS i s not functi onal . The standard brake
system and the abi l i ty to stop the car may not be
affected i f onl y the ABS Warni ng Lamp i s on.
Di scuss wi th the owner of the vehi cl e or note any
other el ectri cal probl ems or condi ti ons that may be
occurri ng on the vehi cl e. They may have an effect on
the anti l ock brake systems functi on.
(1) Turn the key to the off posi ti on and then back
to the on posi ti on. Note whether the ABS Warni ng
Lamp conti nues to stay on. I f i t does, refer to the
di agnosti c manual coveri ng the I TT Teves Mark 20
ABS system for the requi red test procedures.
(2) I f the ABS Warni ng Lamp goes out, shi ft i nto
gear and dri ve the car to a speed of 20 kph (12 mph)
to compl ete the ABS start up cycl e. I f at thi s ti me the
ABS Warni ng Lamp goes on refer to the I TT Teves
Mark 20 Di agnosti c Manual .
(3) I f the ABS Warni ng Lamp remai ns OUT, dri ve
the vehi cl e a short di stance. Duri ng thi s test dri ve be
sure that the vehi cl e achi eves at l east 40 mph. Brake
to at l east one compl ete stop i n an ABS cycl e, and
agai n accel erate to 25 mph.
(4) I f a functi onal probl em wi th the ABS system i s
determi ned whi l e test dri vi ng a vehi cl e, refer to the
di agnosti c manual coveri ng the I TT Teves Mark 20
ABS system for the requi red test procedures and
proper use of the DRB di agnosti c scan tool .
ABS SERVICE PRECAUTIONS
The ABS uses an el ectroni c control modul e, the
CAB. Thi s modul e i s desi gned to wi thstand normal
current draws associ ated wi th vehi cl e operati on.
Care must be taken to avoi d overl oadi ng the CAB
ci rcui ts. In testing for open or short circuits, do
not ground or apply voltage to any of the cir-
cuits unless instructed to do so for a diagnostic
procedure. These ci rcui ts shoul d onl y be tested
usi ng a hi gh i mpedance mul ti -meter or the DRB
tester as descri bed i n thi s secti on. Power shoul d
never be removed or appl i ed to any control modul e
wi th the i gni ti on i n the ON posi ti on. Before removi ng
or connecti ng battery cabl es, fuses, or connectors,
al ways turn the i gni ti on to the OFF posi ti on.
CAUTION: Use only factory wiring harnesses. Do
not cut or splice wiring to the brake circuits. The
addition of after-market electrical equipment (car
phone, radar detector, citizen band radio, trailer
lighting, trailer brakes, ect.) on a vehicle equipped
with antilock brakes may affect the function of the
antilock brake system.
SERVICE PROCEDURES
BRAKE FLUID LEVEL INSPECTION
CAUTION: Use only Mopar brake fluid or an equiv-
alent from a tightly sealed container. Brake fluid
must conform to DOT 3 specifications. Do not use
petroleum-based fluid because seal damage in the
brake system will result.
For the speci fi c procedure coveri ng the i nspecti on
of the brake fl ui d l evel and addi ng brake fl ui d to the
reservoi r, refer to the Servi ce Adjustments Secti on i n
BLEEDING TEVES MARK 20 HYDRAULIC SYSTEM
The base brake system must be bl ed anyti me ai r i s
permi tted to enter the hydraul i c system, due to di s-
connecti on of brake l i nes, hoses or components. The
ABS system, parti cul arl y the HCU, shoul d onl y be
bl ed when the HCU i s repl aced or removed from the
vehi cl e, or i f there i s reason to bel i eve the HCU has
i ngested ai r. Under most ci rcumstances that woul d
requi re brake bl eedi ng, onl y the base brake system
needs to be bl ed.
I t i s i mportant to note that excessi ve ai r i n the
brake system wi l l cause a soft or spongy feel i ng
brake pedal .
Duri ng bl eedi ng operati ons, be sure that the brake
fl ui d l evel remai ns cl ose to the FULL l evel i n the res-
ervoi r. Check the fl ui d l evel peri odi cal l y duri ng the
bl eedi ng procedure and add DOT 3 brake fl ui d as
requi red.
The Teves Mark 20 ABS hydraul i c system and the
base brake hydraul i c system must be bl ed as two
i ndependent braki ng systems. The non ABS porti on
of the brake system i s to be bl ed the same as any
non ABS system. Refer to the Servi ce Adjustments
secti on i n thi s manual for the proper bl eedi ng proce-
dure to be used. Thi s brake system can be ei ther
pressure bl ed or manual l y bl ed.
The ABS porti on of the brake system MUST be
bl ed separatel y. Thi s bl eedi ng procedure requi res the
use of the DRB Di agnosti c Tester and the bl eedi ng
sequence procedure outl i ned bel ow.
ABS BLEEDING PROCEDURE
When bl eedi ng the ABS system, the fol l owi ng
bl eedi ng sequence MUST be fol l owed to i nsure com-
pl ete and adequate bl eedi ng. The ABS system can be
bl ed usi ng a manual bl eedi ng procedure or standard
pressure bl eedi ng equi pment.
NS BRAKES 5 - 99
I f the brake system i s to be bl ed usi ng pressuri zed
bl eedi ng equi pment, refer to Bl eedi ng Brake System
i n the Servi ce Adjustments secti on at the begi nni ng
of thi s group for proper equi pment usage and proce-
dures.
(1) Assembl e and i nstal l al l brake system compo-
nents on the vehi cl e maki ng sure al l hydraul i c fl ui d
l i nes are i nstal l ed and properl y torqued.
(2) Connect the DRB Di agnosti cs Tester to the
di agnosti cs connector. The Teves Mark 20 ABS di ag-
nosti c connector i s l ocated under the i nstrument
panel to the l eft of the steeri ng col umn cover.
(3) Usi ng the DRB, check to make sure the CAB
does not have any faul t codes stored. I f i t does,
remove them usi ng the DRB.
WARNING: WHEN BLEEDING THE BRAKE SYS-
TEM WEAR SAFETY GLASSES. A CLEAR BLEED
TUBE MUST BE ATTACHED TO THE BLEEDER
SCREWS AND SUBMERGED IN A CLEAR CON-
TAINER FILLED PART WAY WITH CLEAN BRAKE
FLUID. DIRECT THE FLOW OF BRAKE FLUID AWAY
FROM THE PAINTED SURFACES OF THE VEHICLE.
BRAKE FLUID AT HIGH PRESSURE MAY COME
OUT OF THE BLEEDER SCREWS WHEN OPENED.
(4) Bl eed the base brake system usi ng the stan-
dard pressure or manual bl eedi ng procedure as out-
l i ned i n the Servi ce Adjustments secti on of thi s
servi ce manual .
(5) Usi ng the DRB, go to the Bl eed ABS routi ne.
Appl y the brake pedal fi rml y and i ni ti ate the Bl eed
ABS cycl e one ti me. Rel ease the brake pedal .
(6) Bl eed the base brake system agai n, as i n step
Step 4 above.
(7) Repeat steps Step 5 and Step 6 above unti l
brake fl ui d fl ows cl ear and i s free of any ai r bubbl es.
Check brake fl ui d l evel i n reservoi r peri odi cal l y to
prevent reservoi r from runni ng l ow on brake fl ui d.
(8) Test dri ve the vehi cl e to be sure brakes are
operati ng correctl y and that brake pedal i s sol i d.
ABS GENERAL SERVICE PRECAUTIONS
CAUTION: Review this entire section prior to per-
forming any mechanical work on a vehicle equipped
with the ITT Tevis Mark 20 ABS brake system. This
section contains information on precautions per-
taining to potential component damage, vehicle
damage and personal injury which could result
when servicing an ABS equipped vehicle.
CAUTION: Only the recommended jacking or hoist-
ing positions for this vehicle are to be used when-
ever it is necessary to lift a vehicle. Failure to raise
a vehicle from the recommended locations could
result in lifting a vehicle by the hydraulic control
unit mounting bracket. Lifting a vehicle by the
hydraulic control unit mounting bracket will result
in damage to the mounting bracket and the hydrau-
lic control unit.
CAUTION: Certain components of the ABS System
are not intended to be serviced individually.
Attempting to remove or disconnect certain system
components may result in improper system opera-
tion. Only those components with approved
removal and installation procedures in this manual
should be serviced.
CAUTION: Brake fluid will damage painted sur-
faces. If brake fluid is spilled on any painted sur-
faces, wash off with water immediately.
CAUTION: When performing any service procedure
on a vehicle equipped with ABS do not apply a 12
volt power source to the ground circuit of the pump
motor in the CAB. Doing this will damage the pump
motor and will require replacement of the HCU.
The fol l owi ng are general cauti ons whi ch shoul d be
observed when servi ci ng the ABS system and/or
other vehi cl e systems. Fai l ure to observe these pre-
cauti ons may resul t i n ABS System component dam-
age.
I f wel di ng work i s to be performed on the vehi cl e,
usi ng an el ectri c arc wel der, the CAB connector
shoul d be di sconnected duri ng the wel di ng operati on.
The CAB 25 way connector connector shoul d never
be connected or di sconnected wi th the i gni ti on swi tch
i n the ON posi ti on.
Many components of the ABS System are not ser-
vi ceabl e and must be repl aced as an assembl y. Do not
di sassembl e any component whi ch i s not desi gned to
be servi ced.
HYDRAULIC CONTROL UNIT
REMOVE
(1) Di sconnect the negati ve (ground) cabl e from
the battery and i sol ate cabl e.
the brake pedal to a posi ti on past the fi rst i nch of
pedal travel . This will prevent brake fluid from
draining out of the master cylinder when the
brake tubes are removed from the HCU.
5 - 100 BRAKES NS
(4) Remove the routi ng cl i p attachi ng the HCU
wi ri ng harness to the HCU mounti ng bracket (Fi g.
19).
CAUTION: Do not apply a 12 volt power source to
any terminals of the 25 way HCU connector when
disconnected.
(5) Remove the 25 way connector (Fi g. 19) from
the CAB. The 25 way connector i s removed from the
CAB usi ng the fol l owi ng procedure. Grasp the l ock
on the 25 way connector (Fi g. 19) and pul l i t as far
out as possi bl e (Fi g. 20). Thi s wi l l rai se and unl ock
the 25 way connector from the socket on the CAB.
the HCU, the HCU must be thoroughly cleaned. This
must be done to prevent dirt particles from falling
into the ports of HCU or entering the brake tubes.
(6) Thoroughl y cl ean al l surfaces of the HCU, and
al l brake tube nuts l ocated on the HCU. Use onl y a
equi val ent to cl ean the HCU.
(7) Remove the brake tubes (6) from the i nl et and
outl et ports on the HCU. (Fi g. 21).
HCU mounti ng bracket to the front suspensi on cross-
member.
(9) Remove HCU and the mounti ng bracket as a
uni t from the vehi cl e.
HCU to the mounti ng bracket. Separate the HCU
(11) Remove the CAB (Fi g. 19) from the bottom of
the HCU for i nstal l ati on on the repl acement HCU.
Refer to Control l er Anti l ock Brakes (CAB) i n the
Fig. 19 CAB 25 Way Connector
Fig. 20 Unlocked 25 Way CAB Connector
Fig. 21 Brake Tube Connections To HCU
Fig. 22 HCU To Suspension Cradle Mounting Bolts
NS BRAKES 5 - 101
INSTALL
(1) I nstal l the CAB (Fi g. 19) on the bottom of the
HCU. Refer to Control l er Anti l ock Brakes (CAB) i n
the Removal And I nstal l ati on Secti on i n thi s group of
the servi ce manual for the requi red procedure.
(2) I nstal l the HCU on the mounti ng bracket (Fi g.
23). I nstal l the 3 bol ts (Fi g. 23) attachi ng the HCU to
the mounti ng bracket. Ti ghten the 3 mounti ng bol ts
CAUTION: The HCU mounting bracket to front sus-
pension cradle mounting bolts have a unique corro-
sion protection coating and a special aluminum
washer. For this reason, only the original, or origi-
nal equipment Mopar replacement bolts can be
used to mount the HCU bracket to the front suspen-
sion crossmember.
(3) I nstal l the HCU and i ts mounti ng bracket as
an assembl y on the front suspensi on crossmember.
I nstal l the 3 bol ts attachi ng the HCU bracket to the
crossmember (Fi g. 22). Ti ghten the 3 mounti ng bol ts
CAUTION: Because of the flexible section in the
primary and secondary brake tubes, and the brake
tubes between the HCU and the proportioning
valve, the brake tubes must be held in proper ori-
entation when tightened and torqued. These tubes
must not contact each other or other vehicle com-
ponents when installed. Also, after the brake tubes
are installed on the HCU, ensure all spacer clips are
reinstalled on the brake tubes.
CAUTION: When installing the chassis brake tubes
on the HCU valve block, they must be located cor-
rectly in the valve block to ensure proper ABS oper-
ation. Refer to (Fig. 21) for the correct chassis
brake tube locations.
NOTE: The chassis brake tube attachment loca-
tions to the HCU, are marked on the bottom of the
HCU mounting bracket.
(4) I nstal l the 6 chassi s brake tubes i nto thei r cor-
rect port l ocati ons on the HCU val ve bl ock as shown
i n (Fi g. 21). Ti ghten the tube nuts to a torque of 17
Nm (145 i n. l bs.).
NOTE: Before installing the 25 way connector in
the CAB be sure the seal is properly installed in the
connector.
(5) I nstal l the 25 way connector (Fi g. 19) on the
CAB usi ng the fol l owi ng procedure. Posi ti on the 25
way connector i n the socket of the CAB and careful l y
push i t down as far as possi bl e. When connector i s
ful l y seated by hand i nto the CAB socket, push i n the
connector l ock (Fi g. 20). Thi s wi l l pul l the connector
i nto the socket of the CAB and l ock i t i n the i nstal l ed
posi ti on.
NOTE: The CAB wiring harness must be clipped to
the HCU mounting bracket. This will ensure the wir-
ing harness is properly routed and does not contact
the brake tubes or the body of the vehicle.
(6) Cl i p the cab wi ri ng harness (Fi g. 19) to the
HCU mounti ng bracket.
(7) I nstal l the routi ng cl i ps (Fi g. 24) on the brake
tubes.
(9) Connect negati ve cabl e back on negati ve post of
the battery.
(10) Bl eed the base brakes and the ABS brakes
hydraul i c system. Refer to the Bl eedi ng ABS System
i n thi s secti on of the manual for the proper bl eedi ng
procedure.
the base and ABS systems.
Fig. 23 HCU Mounting Bolts
Fig. 24 Brake Tube Routing Clips
5 - 102 BRAKES NS
CONTROLLER ANTILOCK BRAKES (CAB)
REMOVE
(1) Di sconnect the negati ve (ground) cabl e from
the battery and i sol ate cabl e.
the brake pedal to a posi ti on past the fi rst i nch of
pedal travel . This will prevent brake fluid from
draining out of the master cylinder when the
brake tubes are removed from the HCU.
CAUTION: Do not apply a 12 volt power source to
any terminals of the 25 way HCU connector when
disconnected.
(4) Remove the 25 way connector (Fi g. 25) from
the CAB l ocated on the bottom of the HCU. The 25
way connector i s removed from the CAB usi ng the
fol l owi ng procedure. Grasp the l ock on the 25 way
connector (Fi g. 25) and pul l i t as far out as possi bl e
(Fi g. 26). Thi s wi l l unl ock and rai se the 25 way con-
nector from the socket on the CAB.
the HCU, the HCU must be thoroughly cleaned. This
must be done to prevent dirt particles from falling
into the ports of HCU or entering the brake tubes.
(5) Thoroughl y cl ean al l surfaces of the HCU, and
al l brake tube nuts l ocated on the HCU. Use onl y a
equi val ent to cl ean the HCU.
(6) Remove the brake tubes (6) from the i nl et and
outl et ports on the HCU. (Fi g. 27).
HCU mounti ng bracket to the front suspensi on cross-
member.
Fig. 25 CAB 25 Way Connector
Fig. 26 Unlocking CAB 25 Way Connector
Fig. 27 Brake Tube Connections To HCU
Fig. 28 HCU To Suspension Cradle Mounting Bolts
NS BRAKES 5 - 103
(8) Remove HCU and the mounti ng bracket as a
uni t from the vehi cl e.
HCU to the mounti ng bracket. Separate the HCU
(10) Unpl ug the pump motor wi ri ng harness (Fi g.
30) from the CAB.
CAB to the val ve bl ock of the HCU.
(12) Remove the CAB from the val ve bl ock of the
HCU (Fi g. 32).
INSTALL
(1) I nstal l the CAB (Fi g. 32) on the val ve bl ock of
the HCU.
(2) I nstal l the 4 bol ts mounti ng the CAB (Fi g. 31)
to the val ve bl ock of the HCU. Ti ghten the CAB
mounti ng bol ts to a torque of 2 Nm (17 i n. l bs.).
(3) Pl ug the pump/motor wi ri ng harness i nto the
CAB (Fi g. 30).
(4) I nstal l the HCU on the mounti ng bracket (Fi g.
29). I nstal l the 3 bol ts (Fi g. 29) attachi ng the HCU to
the mounti ng bracket. Ti ghten the 3 mounti ng bol ts
CAUTION: The HCU mounting bracket to front sus-
pension cradle mounting bolts have a unique corro-
sion protection coating and a special aluminum
washer. For this reason, only the original, or origi-
nal equipment Mopar replacement bolts can be
used to mount the HCU bracket to the front suspen-
sion crossmember.
(5) I nstal l the HCU and i ts mounti ng bracket as
an assembl y on the front suspensi on crossmember.
I nstal l the 3 bol ts attachi ng the HCU bracket to the
crossmember (Fi g. 28). Ti ghten the 3 mounti ng bol ts
Fig. 29 HCU Mounting Bolts
Fig. 30 Pump Motor To CAB Wiring Harness
Fig. 31 CAB Attaching Bolts
Fig. 32 Remove/Install CAB
5 - 104 BRAKES NS
CAUTION: Because of the flexible section in the
primary and secondary brake tubes, and the brake
tubes between the HCU and the proportioning
valve, the brake tubes must be held in proper ori-
entation when tightened and torqued. These tubes
must not contact each other or other vehicle com-
ponents when installed.
CAUTION: When installing the chassis brake tubes
on the HCU valve block, they must be located cor-
rectly in the valve block to ensure proper ABS oper-
ation. Refer to (Fig. 27) for the correct chassis
brake tube locations.
NOTE: The chassis brake tube attachment loca-
tions to the HCU, are marked on the bottom of the
HCU mounting bracket.
(6) I nstal l the 6 chassi s brake tubes i nto thei r cor-
rect port l ocati ons on the HCU val ve bl ock as shown
i n (Fi g. 27). Ti ghten the tube nuts to a torque of 17
Nm (145 i n. l bs.).
NOTE: Before installing the 25 way connector in
the CAB be sure the seal is properly installed in the
connector.
(7) I nstal l the 25 way connector on the CAB usi ng
the fol l owi ng procedure. Posi ti on the 25 way connec-
tor i n the socket of the CAB and careful l y push i t
down as far as possi bl e. When connector i s ful l y
seated by hand i nto the CAB socket, push i n the con-
nector l ock (Fi g. 26). Thi s wi l l pul l the connector i nto
the socket of the CAB and l ock i t i n the i nstal l ed
posi ti on.
(8) I nstal l the routi ng cl i ps (Fi g. 33) on the brake
tubes.
(10) Connect negati ve cabl e back on negati ve post
of the battery.
(11) Bl eed the base brakes and the ABS brakes
hydraul i c system. Refer to the Bl eedi ng ABS System
i n thi s secti on of the manual for the proper bl eedi ng
procedure.
of the base and ABS brake systems.
WHEEL SPEED SENSOR (FRONT)
REMOVE
thi s vehi cl e.
vehi cl e.
(3) Remove the 2 screws (Fi g. 34) attachi ng front
channel bracket and grommet retai ner to the outer
frame rai l .
CAUTION: When disconnecting the wheel speed
sensor from vehicle wiring harness, be careful not
to damage pins on connector
(4) Pul l speed sensor cabl e grommet and connector
through the hol e i n the strut tower (Fi g. 35). Di scon-
nect speed sensor cabl e from vehi cl e wi ri ng harness
(Fi g. 35).
(5) Remove the wheel speed sensor head to steer-
i ng knuckl e attachi ng bol t (Fi g. 36).
(6) Remove sensor head from steeri ng knuckl e. I f
the sensor has sei zed, due to corrosi on, DO NOT
USE PLIERS ON SENSOR HEAD. Use a hammer
and a punch and tap edge of sensor ear, rocki ng the
sensor si de to si de unti l free.
Fig. 33 Brake Tube Routing Clips
Fig. 34 Front Speed Sensor Cable Channel Bracket
NS BRAKES 5 - 105
(7) Remove the wheel speed sensor cabl e grommets
from the retai ni ng bracket (Fi g. 37).
(8) Remove front wheel speed sensor assembl y
from the vehi cl e.
INSTALL
CAUTION: Proper installation of wheel speed sen-
sor cables is critical to continued system operation.
Be sure that cables are installed in retainers. Fail-
ure to install cables in retainers as shown in this
section may result in contact with moving parts
and/or over extension of cables, resulting in an
open circuit.
(1) Connect the front wheel speed sensor cabl e to
the vehi cl e wi ri ng harness connector (Fi g. 35). Be
sure speed sensor cabl e connector i s ful l y seated and
l ocked i nto vehi cl e wi ri ng harness connector, then
i nsert cabl e and grommet i nto hol e i n strut tower
(Fi g. 35).
CAUTION: When installing channel bracket, do not
pinch the speed sensor cable under the channel
bracket.
(2) I nstal l the channel bracket and grommet
retai ner on the frame rai l (Fi g. 34).
(3) I nstal l the 2 bol ts (Fi g. 34) attachi ng the chan-
nel bracket to frame. Ti ghten the 2 attachi ng bol ts to
a torque of 11 Nm (95 i n. l bs.).
(4) I nsert speed sensor cabl e grommets i nto i nter-
medi ate bracket on strut (Fi g. 37). Route cabl e from
strut to steeri ng knuckl e on the rearward si de of the
stabi l i zer bar l i nk.
(5) I nstal l the wheel speed sensor to steeri ng
knuckl e attachi ng bol t (Fi g. 36). Ti ghten the speed
sensor attachi ng bol t to a torque of 12 Nm (105 i n.
l bs.)
(6) Check the ai r gap between the face of the
wheel speed sensor and the top surface of the tone-
wheel . Ai r gap must be l ess then the maxi mum
al l owabl e tol erance of 1.2 mm (.047 i n.).
(7) I nstal l the wheel and ti re assembl y on vehi cl e.
the base and ABS brake systems.
WHEEL SPEED SENSOR (REAR FWD)
REMOVE
vehi cl e.
vehi cl e.
Fig. 35 Speed Sensor Cable To Vehicle Wiring
Harness
Fig. 36 Front Wheel Speed Sensor Attaching Bolt
Fig. 37 Front Wheel Speed Sensor Cable Routing
5 - 106 BRAKES NS
CAUTION: When unplugging speed sensor cable
from vehicle wiring harness be careful not to dam-
age pins on the electrical connectors. Also inspect
connectors for any signs of previous damage.
(3) Remove grommet from fl oor pan of vehi cl e and
unpl ug speed sensor cabl e connector from vehi cl e
wi ri ng harness (Fi g. 38).
CAUTION: When removing rear wheel speed sen-
sor cable from routing clips on rear brake flex hose,
be sure not to damage the routing clips. Routing
clips are molded onto the hose and will require
replacement of the brake flex hose if damaged dur-
ing removal of the speed sensor cable.
(4) Careful l y remove the speed sensor cabl e from
the rear brake fl ex hose routi ng cl i ps (Fi g. 39).
(5) I f removi ng the ri ght rear speed sensor cabl e,
remove the speed sensor cabl e grommet from the
axl e fl ange, the brake tube cl i p and the routi ng cl i p
from the track bar bracket on the axl e (Fi g. 40).
(6) Remove the 2 rear wheel speed sensor cabl e/
brake tube routi ng cl i ps (Fi g. 41). Then un-cl i p the
speed sensor cabl e from the routi ng cl i ps on rear
brake tube (Fi g. 41).
CAUTION: If the speed sensor has seized, due to
corrosion, do not use pliers on speed sensor head
in a attempt to remove it. Use a hammer and a
punch and tap edge of sensor, rocking the sensor
from side to side until free.
(7) Remove the wheel speed sensor head to rear
beari ng attachi ng bol t (Fi g. 42). I f sensor head does
not come l oose, do not use pl i ers. Tap wi th screw
dri ver and hammer.
(8) Remove the wheel speed sensor head from the
rear beari ng assembl y.
(9) Remove speed sensor assembl y from vehi cl e.
Fig. 38 Rear Speed Sensor Cable Connection To
Vehicle Wiring Harness
Fig. 39 Speed Sensor Cable Attachment To Brake
Flex Hose
Fig. 40 Right Rear Speed Sensor Cable Routing
Fig. 41 Rear Speed Sensor Routing Brackets And
Clips
NS BRAKES 5 - 107
INSTALL
open circuit.
(1) I nstal l wheel speed sensor head. Note, the pl as-
ti c anti rotati on pi n must be ful l y seated pri or to
i nstal l i ng the attachi ng bol t.
CAUTION: Prior to installing the speed sensor
head attaching bolt, the plastic anti-rotation pin
must be fully seated into the bearing flange.
(2) I nstal l the wheel speed sensor head to beari ng
fl ange attachi ng bol t (Fi g. 42). Ti ghten the attachi ng
bol t to a torque 12 Nm (105 i n. l bs.)
(4) I nstal l the 2 routi ng brackets attachi ng the
speed sensor cabl e and brake tube to the rear axl e
(Fi g. 41). The rear wheel speed sensor cable
should be routed under the rear brake tube
(Fig. 41).
CAUTION: When installing rear wheel speed sen-
sor cable in the routing clips on rear brake flex
hose, be sure not to damage the routing clips.
Routing clips are molded onto the hose and will
require replacement of the brake flex hose if dam-
aged during installation of the wheel speed sensor
cable.
(5) I nstal l speed sensor cabl e i nto routi ng cl i ps on
rear brake fl ex hose (Fi g. 41).
(6) I f i nstal l i ng a ri ght rear speed sensor cabl e,
i nstal l the speed sensor cabl e grommet on the axl e
brake fl ex hose bracket (Fi g. 40).
CAUTION: The wheel speed sensor cable connec-
tors for the left and right rear wheel speed sensors
are keyed differently. Therefore, when connecting a
wheel speed sensor cable to the vehicle wiring har-
ness, do not force the connectors together. If the
connectors are forced together, damage to the con-
nectors will occur.
(7) Pl ug speed sensor cabl e connector i nto vehi cl e
wi ri ng harness (Fi g. 38). Be sure speed sensor
cable connector is fully seated and locked into
vehicle wiring harness connector.
(8) I nstal l the speed sensor cabl e grommet i nto the
body, bei ng sure the grommet i s ful l y seated i nto the
body hol e.
(9) I nstal l the ti re and wheel assembl y on vehi cl e.
of the base and ABS braki ng systems.
WHEEL SPEED SENSOR (REAR AWD)
REMOVE
vehi cl e.
vehi cl e.
CAUTION: When unplugging speed sensor cable
from vehicle wiring harness be careful not to dam-
age pins on the electrical connectors. Also inspect
connectors for any signs of previous damage.
(3) Remove grommet from fl oor pan of vehi cl e and
unpl ug speed sensor cabl e connector from vehi cl e
wi ri ng harness (Fi g. 43).
CAUTION: When removing rear wheel speed sen-
sor cable from routing clips on rear brake flex hose,
be sure not to damage the routing clips. Routing
clips are molded onto the hose and will require
replacement of the brake flex hose if damaged dur-
ing removal of the speed sensor cable.
Fig. 42 Rear Wheel Speed Sensor Attaching Bolt
5 - 108 BRAKES NS
(4) Careful l y remove the speed sensor cabl e from
the rear brake fl ex hose routi ng cl i ps (Fi g. 44).
(5) Remove the rear wheel speed sensor cabl e/
brake tube routi ng cl i ps (Fi g. 45). Then un-cl i p the
speed sensor cabl e from the routi ng cl i ps on rear
brake tube (Fi g. 45).
CAUTION: If the speed sensor has seized, due to
corrosion, do not use pliers on speed sensor head
in a attempt to remove it. Use a hammer and a
punch and tap edge of sensor, rocking the sensor
from side to side until free.
(6) Remove the wheel speed sensor attachi ng bol t
(Fi g. 46). I f sensor head does not come l oose, do not
use pl i ers on the sensor head to l oosen. Tap sensor
head from si de to si de to l oosen.
(7) Remove the wheel speed sensor from the rear
beari ng assembl y.
(8) Remove the speed sensor assembl y from the
vehi cl e.
INSTALL
open circuit.
(1) I nstal l wheel speed sensor head. Note, the pl as-
ti c anti rotati on pi n must be ful l y seated pri or to
i nstal l i ng the attachi ng bol t.
CAUTION: Prior to installing the speed sensor
head attaching bolt, the plastic anti-rotation pin
must be fully seated into the bearing flange.
Fig. 43 Speed Sensor Cable Connection To Vehicle
Wiring Harness
Fig. 44 Speed Sensor Cable Attachment To Brake
Flex Hose
Fig. 45 Rear Speed Sensor Routing Brackets And
Clips
Fig. 46 Speed Sensor Attaching Bolt
NS BRAKES 5 - 109
(2) I nstal l the wheel speed sensor head attachi ng
bol t (Fi g. 46). Ti ghten the attachi ng bol t to a torque
12 Nm (105 i n. l bs.)
(4) I nstal l the routi ng brackets attachi ng the speed
sensor cabl e and brake tube to the rear axl e (Fi g.
45). The rear wheel speed sensor cable should
be routed under the rear brake tube (Fig. 45).
CAUTION: When installing rear wheel speed sen-
sor cable in the routing clips on rear brake flex
hose, be sure not to damage the routing clips.
Routing clips are molded onto the hose and will
require replacement of the brake flex hose if dam-
aged during installation of the wheel speed sensor
cable.
(5) I nstal l speed sensor cabl e i nto routi ng cl i ps on
rear brake fl ex hose (Fi g. 44).
CAUTION: The wheel speed sensor cable connec-
tors for the left and right rear wheel speed sensors
are keyed differently. Therefore, when connecting a
wheel speed sensor cable to the vehicle wiring har-
ness, do not force the connectors together. If the
connectors are forced together, damage to the con-
nectors will occur.
(6) Pl ug speed sensor cabl e connector i nto vehi cl e
wi ri ng harness (Fi g. 43). Be sure speed sensor
cable connector is fully seated and locked into
vehicle wiring harness connector.
(7) I nstal l the speed sensor cabl e grommet i nto the
body, bei ng sure the grommet i s ful l y seated i nto the
body hol e.
(8) I nstal l the ti re and wheel assembl y on vehi cl e.
the base and ABS braki ng systems.
TONE WHEEL (REAR FWD)
REMOVE
(2) Remove the wheel and ti re assembl y.
(3) Remove rear brake drum from the hub/beari ng
assembl y.
(4) Remove the rear wheel speed sensor from the
rear hub/beari ng fl ange (Fi g. 47). Thi s wi l l prevent
damage to the speed sensor duri ng removal and
i nstal l ati on of the hub/beari ng assembl y.
beari ng assembl y to the fl ange of the rear axl e.
(6) Remove the hub/beari ng assembl y from the
rear axl e and brake support pl ate (Fi g. 49).
Fig. 49 Removing Rear Hub/Bearing From Axle
5 - 110 BRAKES NS
(7) I nstal l wheel l ug nuts on 3 of the wheel mount-
i ng studs to protect the stud threads from damage by
the vi se jaws. Mount the hub/beari ng assembl y i n a
vi se (Fi g. 50). Usi ng Pul l er, Speci al Tool C-4693
i nstal l ed as shown i n (Fi g. 50) remove the tone wheel
from the hub/beari ng assembl y.
INSTALL
(1) Pl ace hub/beari ng assembl y i n an arbor press
supported by Recei ver, Speci al Tool , 6062A3 (Fi g.
51). Posi ti on Dri ver, Speci al Tool 69081 wi th under-
cut si de faci ng up (Fi g. 51) on top of the tone wheel .
(2) Press the tone wheel onto the hub/beari ng
assembl y unti l i t i s fl ush wi th the end of hub shaft
(Fi g. 52).
(3) I nstal l the 4 hub/beari ng to axl e fl ange mount-
i ng bol ts i nto the 4 mounti ng hol es i n the fl ange of
the rear axl e.
mounti ng bol ts i nstal l ed i n the fl ange of the rear
axl e.
(5) Al i gn the rear hub/beari ng assembl y wi th the 4
mounti ng bol ts and start mounti ng bol ts i nto hub/
beari ng assembl y. Ti ghten the 4 bol ts i n a cri ss-cross
pattern unti l the hub/beari ng and brake support
pl ate i s ful l y and squarel y seated onto fl ange of rear
axl e.
i n. l bs.).
(9) I nstal l the brake drum onto the rear hub/bear-
i ng assembl y.
(10) I nstal l rear wheel and ti re assembl y, ti ghten
wheel stud nuts to 129 Nm (95 ft. l bs.).
TONE WHEEL (REAR AWD)
The rear tone wheel on al l wheel dri ve appl i cati ons
i s an i ntegral part of each rear axl e outer C/V joi nt.
I f the rear tone wheel on an al l wheel dri ve vehi cl e
requi res repl acement i t can not be repl ace as a sep-
arate component of the rear axl e. Tone wheel repl ace-
ment wi l l requi re the repl acement of the rear axl e.
Refer to Di fferenti al And Dri vel i ne i n thi s servi ce
manual for the rear axl e repl acement procedure.
Fig. 50 Tone Wheel Removal From Hub/Bearing
Assembly
Fig. 51 Installing Tone Wheel On Hub/Bearing
Assembly
Fig. 52 Correctly Installed Tone Wheel
NS BRAKES 5 - 111
SPECIFICATIONS
SPEED SENSOR TONE WHEEL RUNOUT
The total i ndi cator runout al l owed for both the
front and rear tone wheel measured usi ng a di al i ndi -
cator i s 0.15 mm (.006 i n.).
WHEEL SPEED SENSOR TO TONE WHEEL
CLEARANCE
FRONT WHEEL
Mi ni mum Cl earance .35mm (.014 i n.)
Maxamum Cl earance 1.2 mm (.047 i n.)
REAR WHEEL
Mi ni mum Cl earance .40mm (.016 i n.)
Maxamum Cl earance 1.2 mm (.047 i n.)
BRAKE FASTENER TORQUE SPECIFICATIONS
DESCRIPTION TORQUE
BRAKE TUBES:
Tube Nuts To Fi tti ngs And
Components . . . . . . . . . . . . . .17 Nm (145 i n. l bs.)
BRAKE HOSE:
To Cal i per Banjo Bol t . . . . . . . . . .48 Nm (35 ft. l bs.)
I ntermedi ate Bracket . . . . . . . . .12 Nm (105 i n. l bs.)
MASTER CYLINDER:
To Vacuum Booster
Mounti ng Nut . . . . . . . . . . . .25 Nm (225 i n. l bs.)
FIXED PROPORTIONING VALVE:
To Frame Rai l Attachi ng
Bol ts . . . . . . . . . . . . . . . . . . . .14 Nm (125 i n. l bs.)
HEIGHT SENSING PROPORTIONING VALVE:
To Mounti ng Bracket
Attachi ng Bol ts . . . . . . . . . . .23 Nm (200 i n. l bs.)
Actuator Assembl y
Adjustment Nut . . . . . . . . . . . . .5 Nm (45 i n. l bs.)
Frame Rai l Bol ts . . . . . . . . . .17 Nm (150 i n. l bs.)
J UNCTION BLOCK (NON-ABS BRAKES)
VACUUM BOOSTER:
To Dash Panel Mounti ng
Nuts . . . . . . . . . . . . . . . . . . . .28 Nm (250 i n. l bs.)
DESCRIPTION TORQUE
REAR WHEEL CYLINDER:
To Support Pl ate Mounti ng
Bol ts . . . . . . . . . . . . . . . . . . . . .8 Nm (75 i n. l bs.)
Bl eeder Screw . . . . . . . . . . . . . . .10 Nm (80 i n. l bs.)
BRAKE SUPPORT PLATE:
To Rear Axl e Mounti ng Bol ts . . .130 Nm (95 ft. l bs.)
DISC BRAKE CALIPER:
Gui de Pi n Bol ts . . . . . . . . . . . . . .41 Nm (30 ft. l bs.)
Bl eeder Screw . . . . . . . . . . . . . .15 Nm (125 i n. l bs.)
Suspensi on Cradl e Bol ts. . . . .28 Nm (250 i n. l bs.)
To Mounti ng Bracket I sol ator
Attachi ng Bol ts . . . . . . . . . . . .11 Nm (97 i n. l bs.)
CAB To HCU Mounti ng Screws . . .2 Nm (17 i n. l bs.)
WHEEL SPEED SENSOR:
To Axl e Or Steeri ng Knuckl e
PARKING BRAKE:
Pedal Assembl y Mounti ng
Bol ts . . . . . . . . . . . . . . . . . . . .28 Nm (250 i n. l bs.)
REAR HUB AND BEARING:
WHEEL:
Stud Lug Nut . . . . . . . .115156 Nm (84-115 ft. l bs.)
5 - 112 BRAKES NS
BRAKES
CONTENTS
page page
GENERAL INFORMATION
BASE BRAKE SYSTEM COMPONENT
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 1
MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . 1
MASTER CYLINDER FLUID LEVEL CHECK . . . 2
REAR DRUM BRAKE ADJ USTMENT . . . . . . . . 1
BRAKE PEDAL TORQUE SHAFT ASSEMBLY . . 4
FRONT PARK BRAKE CABLE AND LEVER
ASSEMBLY-RHD&LHD VEHICLES . . . . . . . . 2
GENERAL INFORMATION
BASE BRAKE SYSTEM COMPONENT DESCRIPTION
The standard brake system on thi s vehi cl e contai ns
the same components as brake systems descri bed i n
group 5 of the servi ce manual , wi th the excepti on of
the brake pedal system and master cyl i nder. These
di fferences are mai nl y rel ated to servi ce procedures.
The major di fferences are as fol l ows:
Use of a torque shaft assembl y to transfer brake
pedal travel to the power brake booster and master
cyl i nder on the l eft si de of the vehi cl e
A uni que power brake booster and master cyl i n-
der.
Refer to the Base Brake System Component
Descri pti on i n the General I nformati on secti on of
group 5 for more i nformati on on components used i n
the base brake system.
MASTER CYLINDER
The master cyl i nder used on thi s vehi cl e functi ons
the same as master cyl i nders used i n other brake
systems. Refer to the Master Cyl i nder i n the Descri p-
ti on and Operati on secti on of group 5 for more i nfor-
mati on.
REAR DRUM BRAKE ADJUSTMENT
The rear drum brakes on front wheel dri ve vehi cl es
automati cal l y adjust, when requi red, duri ng the nor-
mal operati on of the vehi cl e every ti me the brakes
are appl i ed. Use the fol l owi ng procedure to test the
operati on of the automati c adjuster.
Pl ace the vehi cl e on a hoi st wi th a hel per i n the
dri vers seat to appl y the brakes. Remove the access
pl ug from the adjustment sl ot i n each brake support
pl ate to provi de vi sual access of brake adjuster star
wheel . Di sconnect parki ng brake cabl e from one si de
of the vehi cl e at the equal i zer under the vehi cl e at
the l eft frame rai l . Worki ng on the si de of the vehi cl e
that parki ng brake cabl e i s connected to, hol d the
adjuster l ever off the star wheel wi th a sui tabl e tool ,
and l oosen the star wheel approxi matel y 30 notches
i n rel ati on to the adjuster l ever. Thi s i s to el i mi nate
the possi bi l i ty that the brake i s al ready properl y
adjusted. Reconnect the parki ng brake cabl e and
repeat the procedure for the other si de of the vehi cl e.
Fig. 1 Master Cylinder Assembly
NS/GS BRAKES 5 - 1
Upon appl i cati on of the brake pedal , the l ever
shoul d move down, turni ng the star wheel . A defi ni te
rotati on of the star wheel shoul d be seen i f the auto-
mati c adjuster i s worki ng properl y. I f no rotati on of
the star wheel i s observed when the pedal i s consec-
uti vel y pressed and rel eased, the respecti ve drum
wi l l have to be removed and the adjuster servi ced.
MASTER CYLINDER FLUID LEVEL CHECK
The master cyl i nder used i n thi s vehi cl e has the
same fl ui d l evel marki ngs as the master cyl i nders
used i n other brake systems on the si de of the fl ui d
resevoi r. Refer to the Master Cyl i nder Fl ui d Level
Check i n the Di agnosi s and Testi ng secti on of group
5 for more i nformati on
FRONT PARK BRAKE CABLE AND LEVER
ASSEMBLY-RHD&LHD VEHICLES
REMOVE
(2) Remove the i ntermedi ate and l eft rear park
2).
(3) Remove the front park cabl e housi ng retai ner
from body outri gger bracket (Fi g. 3). Cabl e i s remov-
abl e by sl i di ng a 14 mm box wrench over cabl e
(4) Remove the two (2) retai ni ng nuts and (2)
retai ni ng bol ts from the bottom of the parki ng brake/
gearshi ft l ever bracket.
(6) Careful l y l i ft the base of the gearshi ft boot
from the gearshi ft consol e to access the screws (Fi g.
4).
Fig. 3 Front Park Brake Cable Attachment To Body
Fig. 4 Console and Gearshift boot
5 - 2 BRAKES NS/GS
(7) Remove the four (4) retai ni ng screws (Fi g. 5).
(8) Pul l the parki ng brake l ever to the up posi -
ti on and l i ft the consol e (Fi g. 5).
(9) Ti l t the base of the gearshi ft boot and careful l y
push through the openi ng i n the consol e whi l e l i fti ng.
(10) Remove the three (3) nuts at the base of the
parki ng brake assembl y.
(11) Rel ease the parki ng brake assembl y and l i ft
assembl y off of the parki ng brake/gearshi ft l ever
bracket.
(12) Unhook the l oop on the end of the parki ng
brake from the equal i zer bar on the parki ng brake/
(13) Compress the parki ng brake cabl e retai ner by
sl i di ng a 14 mm box wrench over the cabl e retai ner
and compress the three (3) retai ni ng fi ngers.
(14) Remove the three (3) screws from the parki ng
brake grommet on the fl oor pan of the passenger
compartment.
(15) Li ft the parki ng brake /gearshi ft l ever bracket
and sl i de the parki ng brake cabl e out.
(16) Pul l the cabl e through the fl oor pan from
i nsi de the vehi cl e.
INSTALL
(1) Pass park brake cabl e assembl y through hol e
i n fl oor pan from the i nsi de of the vehi cl e.
(2) Pass cabl e strand button through the hol e i n
the pedal assembl y bracket.
(3) I nstal l parki ng brake cabl e to the brake/gear-
shi ft l ever bracket by l i fti ng the bracket and sl i di ng
the cabl e i n.
(4) I nstal l the three (3) screws to the parki ng
brake grommet on the fl oor pan of the passenger
compartment.
(5) Compress the parki ng brake cabl e retai ner by
sl i di ng a 14 mm box wrench over the cabl e retai ner
and compress the three (3) retai ni ng fi ngers.
(6) Hook the l oop on the end of the parki ng brake
to the equal i zer bar on the parki ng brake/gearshi ft
l ever bracket.
(7) Attach the parki ng brake assembl y and pl ace
assembl y on the parki ng brake/gearshi ft l ever
bracket.
(8) I nstal l the three (3) nuts at the base of the
parki ng brake assembl y.
(9) Pul l the parki ng brake l ever to the up posi -
ti on.
(10) Pl ace the consol e over the parki ng brake/gear-
shi ft l ever and ti l t the base of the gearshi ft boot and
careful l y pul l i t through the openi ng i n the consol e.
(11) I nstal l the four (4) retai ni ng screws (Fi g. 5).
(12) Careful l y press the three (3) cl i ps at the base
of the gearshi ft boot i nto the sl ots on the gearshi ft
consol e.
(13) Rai se the vehi cl e.
(14) i nstal l the two (2) retai ni ng nuts and (2)
retai ni ng bol ts to the bottom of the parki ng brake/
(15) I nstal l the front park cabl e housi ng retai ner
to the body outri gger bracket (Fi g. 3). Cabl e i s
i nstal l ed by sl i di ng a 14 mm box wrench over cabl e
(16) I nstal l the i ntermedi ate and l eft rear park
brake cabl e to the park brake cabl e equal i zer (Fi g. 2).
Fig. 5 Console Retaining Screws
NS/GS BRAKES 5 - 3
BRAKE PEDAL TORQUE SHAFT ASSEMBLY
REMOVE
(1) Di sconnect Brake Pedal Swi tch El ectri cal Con-
nector
(2) Loosen the si x (6) retai ni ng nuts from the
Brake Pedal Bracket. Do not remove nuts from studs.
(Fi g. 6)
(3) Remove steeri ng col umn i ntermedi ate shaft.
Loosen 72 and 36 way el ectri cal connector brackets.
Move components out of the way of the brake pedal
bracket.
(4) Access the brake booster bracket i nsi de the
passenger compartment. Remove the retai ni ng cl i p
from brake pedal torque shaft. Discard retaining
clip. It is not to be re-used. Replace only with a
new clip when reassembled. (Fi g. 7)
(5) Loosen the retai ni ng nut (1) from the Brake
Booster Bracket i n the engi ne compartment. Do not
remove nut from stud. Loosen the four Brake Booster
retai ni ng nuts from i nsi de the passenger compart-
ment. Do not remove nuts from stud (Fi g. 6)
(6) The pedal arm, l i nk and pedal bracket can be
di sconnected from the torque shaft to make i t easi er
to remove.
(7) Remove torque shaft from vehi cl e
INSTALL
(1) I nstal l torque shaft. Reconnect pedal arm, l i nk
and pedal bracket assembl y to torque shaft as neces-
sary.
(2) Ti ghten the retai ni ng nut (1) for the Brake
Booster Bracket i n the engi ne compartment. Ti ghten
the four (4) Brake Booster retai ni ng nuts from i nsi de
the passenger compartment.
(3) I nstal l new retai ni ng cl i p on torque shaft.
(4) I nstal l steeri ng col umn i ntermedi ate shaft.
I nstal l 72 and 36 way connector brackets.
(5) Ti ghten the si x (6) retai ni ng nuts for the Brake
Pedal Bracket assembl y.
(6) Connect the Brake Pedal Swi tch connector.
Fig. 6 Torque Shaft and Brake Pedal Assembly
Fig. 7 Brake Vacuum Booster Bracket
5 - 4 BRAKES NS/GS
CLUTCH
CONTENTS
page page
GENERAL INFORMATION
CLUTCH COMPONENTS . . . . . . . . . . . . . . . . . . 1
CLUTCH DISC AND COVER APPLICATION . . . 3
CLUTCH REPLACEMENT . . . . . . . . . . . . . . . . . 3
CLUTCH PEDAL POSITION SWITCH . . . . . . . . 4
CLUTCH RELEASE SYSTEM . . . . . . . . . . . . . . 4
CLASHINTOREVERSE
COMPLAINTS . . . . . . . . . . . . . . . . . . . . . . . . 8
CLUTCH CHATTER COMPLAINTS . . . . . . . . . . 8
CLUTCH COVER AND DISC RUNOUT . . . . . . . 8
CLUTCH DIAGNOSIS . . . . . . . . . . . . . . . . . . . . 6
CLUTCH PEDAL POSITION SWITCH . . . . . . . . 4
DRIVE PLATE MISALIGNMENT . . . . . . . . . . . . 7
CLUTCH ASSEMBLY (2.5L DIESEL) . . . . . . . 13
CLUTCH CABLE SYSTEM LHD . . . . . . . . . . 8
CLUTCH PEDAL POSITION SWITCH . . . . . . . 10
CLUTCH RELEASE BEARING AND FORK . . . 14
HYDRAULIC CLUTCH LINKAGE SYSTEM
RHD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
MASTER CYLINDER SYSTEM
RHD . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
MODULAR CLUTCH ASSEMBLY (2.0L AND
2.4L GASOLINE) . . . . . . . . . . . . . . . . . . . . . 13
QUICK CONNECT COUPLING
RHD . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
SLAVE CYLINDER ASSEMBLY
RHD . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
CLEANING PRECAUTIONS . . . . . . . . . . . . . . . 15
CLUTCH CONTAMINATION . . . . . . . . . . . . . . 15
ADJUSTMENTS
CLUTCH CABLE LHD . . . . . . . . . . . . . . . . 16
CLUTCH PEDAL POSITION SWITCH . . . . . . . 16
SPECIFICATIONS
CLUTCH TIGHTENING REFERENCE . . . . . . . . 16
GENERAL INFORMATION
CLUTCH COMPONENTS
The cl utch used i n the 2.0 l i ter and 2.4 l i ter gaso-
l i ne engi ne i s a si ngl e, dry-di sc modul ar cl utch
assembl y. The modul ar cl utch assembl y combi nes the
pressure pl ate cover, pressure pl ate, di sc, and fl y-
wheel i nto one uni t. The uni t ri des on the i nput shaft
of the transmi ssi on and i s bol ted to the dri ve pl ate
mounted on the rear of the crankshaft. The cl utch
used i n the 2.5 l i ter di esel engi ne i s a conventi onal
cl utch and pressure pl ate arrangement.
CLUTCH CABLE AND PEDAL LHD
The cl utch cabl e has a uni que sel f-adjuster mecha-
ni sm bui l t i nto the cabl e whi ch compensates for
cl utch di sc wear. The cabl e requi res no mai ntenance
or l ubri cati on. There are no servi ceabl e components
on the cabl e assembl y.
The cl utch pedal i s connected to the cabl e through
a pl asti c spacer (Fi g. 1). The upper end of the cl utch
pedal pi vots i n the pedal bracket on two nyl on bush-
i ngs and a shaft (Fi g. 2). These bushi ngs are greased
duri ng assembl y and do not requi re peri odi c l ubri ca-
ti on.
Fig. 1 Upstop/Spacer and Cable LHD
NS/GS CLUTCH 6 - 1
The cl utch pedal on the 2.0L i s fi tted wi th a return
spri ng (Fi g. 3). The spri ng hook that attaches to the
pedal i s coated wi th nyl on. Push the hook al l the way
through the hol e i n the pedal to prevent i t from
wal ki ng out. No servi ce l ubri cati on i s requi red.
The cl utch pedal on the 2.4L and 2.5L VM di esel i s
fi tted wi th an assi st spri ng (Fi g. 4) to reduce cl utch
pedal effort. The assi st spri ng has two pl asti c end fi t-
ti ngs whi ch l ocate to pi ns on the cl utch pedal and
bracket. The pl asti c whi ch the fi tti ngs are made of
i ncl udes PTFE l ubri cant. No servi ce l ubri cati on i s
requi red.
HYDRAULIC LINKAGE AND COMPONENTS
RHD
The hydraul i c cl utch l i nkage i s a prefi l l ed system
free of ai r, contami nati on, and l eaks. There i s no rou-
ti ne mai ntenance requi red. The hydraul i c cl utch l i nk-
age i s servi ced as an assembl y and the i ndi vi dual
components cannot be overhaul ed or servi ced sepa-
ratel y. The hydraul i c l i nkage consi sts of a cl utch
master cyl i nder wi th i ntegral reservoi r, a cl utch sl ave
cyl i nder and an i nterconnecti ng fl ui d l i ne wi th qui ck
di sconnect coupl i ng (Fi g. 5).
The cl utch master cyl i nder push rod i s connected
to the cl utch pedal (Fi g. 6). The cl utch pedal i s fi tted
wi th a return spri ng. The spri ng hook that attaches
to the pedal i s coated wi th nyl on. No servi ce l ubri ca-
ti on i s necessary. The sl ave cyl i nder push rod i s con-
nected to the cl utch rel ease fork (Fi g. 5).
Fig. 2 Clutch Pedal Components LHD
Fig. 3 Clutch Pedal Return Spring 2.0L LHD
Fig. 4 Assist Spring 2.4L and 2.5L VM Diesel LHD
6 - 2 CLUTCH NS/GS
CLUTCH DISC AND COVER APPLICATION
The 2.0 l i ter and 2.4 l i ter gasol i ne engi nes use a
240 mm (9.5 i n.) modul ar cl utch assembl y. The 2.5
l i ter di esel engi ne uses a 240 mm (9.5 i n.) standard
cl utch and pressure pl ate arrangement. Al though the
cl utches are the same si ze they do not i nterchange.
CLUTCH REPLACEMENT
The transaxl e must be removed to servi ce the
cl utch assembl y, fork, or beari ng.
Fig. 5 Hydraulic Clutch Linkage System RHD
Fig. 6 Clutch Master Cylinder Mounting RHD
NS/GS CLUTCH 6 - 3
CLUTCH RELEASE SYSTEM
CLUTCH CABLE LHD
The manual transaxl e cl utch rel ease system has a
uni que sel f-adjusti ng mechani sm to compensate for
cl utch di sc wear (Fi g. 7). Thi s adjuster mechani sm i s
l ocated wi thi n the cl utch cabl e assembl y. The prel oad
spri ng mai ntai ns tensi on on the cabl e. Thi s tensi on
keeps the cl utch rel ease beari ng conti nuousl y l oaded
agai nst the fi ngers of the cl utch cover assembl y.
HYDRAULIC CLUTCH RHD
Leverage, cl ampi ng force, and fri cti on are what
make the cl utch work. The di sc serves as the fri cti on
el ement and a di aphragm spri ng and pressure pl ate
provi de the cl ampi ng force. The cl utch pedal , hydrau-
l i c l i nkage, rel ease l ever and beari ng provi de the
l everage to di sengage and engage the modul ar cl utch
assembl y.
The modul ar cl utch assembl y contai ns the cover,
di aphragm spri ng, pressure pl ate, di sc and fl ywheel
i n one uni t. The modul ar cl utch al so uses a dri ve
pl ate and i s bol ted to and dri ven by the dri ve pl ate.
The cl utch l i nkage uses hydraul i c pressure to oper-
ate the cl utch. The cl utch master cyl i nder push rod i s
connected to the cl utch pedal and the sl ave cyl i nder
push rod i s connected to the rel ease l ever i n the
cl utch housi ng.
Depressi ng the cl utch pedal devel ops fl ui d pressure
i n the cl utch master cyl i nder. Thi s pressure i s trans-
mi tted to the sl ave cyl i nder through a connecti ng
l i ne. I n turn, the sl ave cyl i nder operates the cl utch
rel ease l ever.
The cl utch rel ease beari ng i s mounted on the
transmi ssi on front beari ng retai ner. The beari ng i s
attached to the rel ease l ever, whi ch moves the bear-
i ng i nto contact wi th the cl utch cover di aphragm
spri ng.
Sl ave cyl i nder force causes the rel ease l ever to
move the rel ease beari ng i nto contact wi th the di a-
phragm spri ng. As addi ti onal force i s appl i ed, the
beari ng presses the di aphragm spri ng fi ngers i nward
on the ful crums. Thi s acti on moves the pressure
pl ate rearward rel i evi ng cl amp force on the di sc. The
cl utch di sc i s di sengaged and not dri ven at thi s poi nt.
The process of cl utch engagement i s si mpl y the
reverse of what occurs duri ng di sengagement. Rel eas-
i ng pedal pressure removes cl utch l i nkage pressure.
The rel ease beari ng moves away from the di aphragm
spri ng whi ch al l ows the pressure pl ate to exert
cl ampi ng force on the cl utch di sc.
CLUTCH PEDAL POSITION SWITCH
The cl utch pedal posi ti on swi tch functi ons as a
safety i nterl ock devi ce. I t prevents possi bl e engi ne
cranki ng wi th the cl utch engaged.
The cl utch pedal posi ti on swi tch i s wi red i n seri es
between the starter rel ay coi l and the i gni ti on
swi tch.
The cl utch pedal posi ti on swi tch i s mounted to a
bracket l ocated behi nd the cl utch pedal . The swi tch
i s hel d i n pl ace by four pl asti c wi ng tabs.
The cl utch pedal posi ti on swi tch I S NOT adjust-
abl e. The pedal bl ade contacts the swi tch i n the down
posi ti on (Fi g. 8).
CLUTCH PEDAL POSITION
SWITCHELECTRICAL TEST
Di sconnect cl utch pedal posi ti on swi tch harness
from i nstrument panel wi ri ng harness. Usi ng an
ohmmeter, check for conti nui ty between the two ter-
mi nal s i n the connector on the swi tch harness. There
shoul d be no conti nui ty between the termi nal s when
Fig. 7 Clutch Cable LHD
Fig. 8 Clutch Pedal Position Switch and
Components LHD Shown
6 - 4 CLUTCH NS/GS
the swi tch i s i n i ts normal (ful l y extended) posi ti on.
When the swi tch i s depressed more than 1.25 mm
(0.050), the ohmmeter shoul d show conti nui ty (zero
ohms).
I f ohmmeter readi ngs do not fal l wi thi n these
ranges, the swi tch i s defecti ve, and must be repl aced.
CLUTCH PEDAL POSITION
SWITCHMECHANICAL TEST
Wi th the park brake set and the vehi cl e IN NEU-
TRAL, turn the key to the start posi ti on. The vehi cl e
shoul d not crank. I f the vehi cl e cranks, the swi tch i s
defecti ve (shorted out) and must be repl aced. I f the
vehi cl e does not crank proceed to the next step.
WARNING: BEFORE PERFORMING THIS STEP, BE
SURE THAT THE AREA IN FRONT OF THE VEHICLE
IS CLEAR OF OBSTRUCTIONS AND PEOPLE. VEHI-
CLE MAY MOVE WHEN PERFORMING THIS TEST.
Wi th the park brake set and the vehi cl e IN GEAR,
turn the key to the start posi ti on and hol d i t there.
Sl owl y depress the cl utch pedal and feel for any
vehi cl e moti on when the starter i s energi zed. I f there
i s no moti on the swi tch i s worki ng properl y.
I f moti on i s fel t, check to see i f the swi tch i s mak-
i ng contact when the pedal i s between 25 mm (1.0
i n.) and 6 mm (0.25 i n.) from the fl oor. I f thi s condi -
ti on i s met, then the probl em i s ei ther the cl utch or
the cl utch actuati on system (See Cl utch Wi l l Not
Di sengage Properl y). I f thi s condi ti on i s not met,
then the swi tch mounti ng tab on the brake bracket i s
bent, and the brake bracket must be repl aced.
I f vehi cl e wi l l not crank, even wi th cl utch pedal
pressed to the fl oor, refer to Servi ce Di agnosi s-
Cl utch Pedal Posi ti on Swi tch chart i n thi s secti on.
SERVICE DIAGNOSISCLUTCH PEDAL POSITION SWITCH
ENGINE WONT CRANK WHEN
CLUTCH PEDAL IS PRESSED TO
THE FLOOR
Switch does not have continuity
when plunger is depressed 1.25 mm
Defective switch. Replace switch.
Switch plunger is not depressed
when clutch pedal is pushed to the
floor
Floor mat interferes with clutch pedal
movement. Move floor mat out of the
way.
Switch mounting bracket is bent.
Replace brake bracket assembly
Problem is related to other
components in the starting circuit
Check other components in the
starting circuit. Refer to Section 8A,
Battery/Starting/Charging System.
NS/GS CLUTCH 6 - 5
CLUTCH DIAGNOSIS
Probl em di agnosi s wi l l general l y requi re a road
test to determi ne the type of faul t. Component
i nspecti on wi l l then determi ne the probl em after road
testi ng.
Dri ve the vehi cl e at normal speeds duri ng road
test. Shi ft the transaxl e through al l gear ranges and
observe cl utch acti on. I f chatter, grab, sl i p, or
i mproper rel ease i s experi enced, remove and i nspect
the cl utch components. I f the probl em i s noi se or
hard shi fti ng, further di agnosi s may be needed. The
transaxl e or other dri vel i ne components may actual l y
be at faul t.
SERVICE DIAGNOSISCLUTCH GRAB/CHATTER
CLUTCH DISC FACING
COVERED WITH OIL OR
GREASE
Oil leak at engine rear main or transaxle
input shaft seal
Correct leak and replace clutch assembly
NO FAULT FOUND WITH
CLUTCH
COMPONENTS
Problem actually related to suspension
or driveline component
Further diagnosis required. Check
engine/transmission mounts, suspension
attaching parts and other driveline
components as needed.
Engine related problems Check EFI and ignition systems
PARTIAL ENGAGEMENT
OF CLUTCH DISC
Clutch cover, spring, or release fingers
bent, distorted (rough handling, improper
assembly)
Replace clutch assembly
Clutch disc damaged or distorted Replace clutch assembly
Clutch misalignment Check alignment and runout of flywheel,
disc, or cover. Check clutch housing to
engine dowels and dowel holes for
damage. Correct as necessary.
SERVICE DIAGNOSISCLUTCH SLIPS
DISC FACING WORN
OUT
Normal wear. Replace clutch assembly.
Driver frequently rides (slips) clutch,
results in rapid wear overheating.
Insufficient clutch cover diaphragm
spring tension
CLUTCH DISC FACING
CONTAMINATED WITH
OIL OR GREASE
Leak at rear main oil seal or transaxle
input shaft seal
Replace leaking seals. Replace clutch
assembly.
Road splash, water entering housing Seal housing. Inspect clutch assembly.
CLUTCH IS RUNNING
PARTIALLY
DISENGAGED
Release bearing sticking or binding,
does not return to normal running
position.
Verify that bearing is actually binding.
Then, replace bearing and transmission
front bearing retainer if sleeve surface is
damaged.
Cable self-adjuster mechanism sticking
or binding causing high preload (LHD
Applications only)
Verify that self-adjuster is free to move
(LHD Applications only)
CLUTCH DISC FACINGS
HAVE FRACTURED INTO
SMALL PIECES
Driver performs a 5-1 downshift at
vehicle speed in excess of 60 miles per
hour
Alert driver to problem cause. Replace
clutch assembly.
Excessive heat from slippage Replace clutch assembly
6 - 6 CLUTCH NS/GS
SERVICE DIAGNOSISIMPROPER CLUTCH RELEASE
CLUTCH DISC BINDS ON
INPUT SHAFT SPLINES
Clutch disc hub splines damaged during
installation
Clean, smooth, and lubricate disc and
shaft splines. Replace clutch assembly
and/or input shaft if splines are severely
damaged.
Input shaft splines rough, damaged. Clean input shaft splines. Then lube.
Corrosion or rust formations on splines
of input shaft and disc
Clean input shaft splines and disc
splines, then lube
CLUTCH DISC RUSTED
TO FLYWHEEL AND/OR
PRESSURE PLATE
Occurs in vehicles stored or not driven
for extended period of time. Also occurs
after steam cleaning if vehicle is not
used for extended period.
CLUTCH WILL NOT
DISENGAGE PROPERLY
Disc bent, distorted during transaxle
installation
Clutch cover diaphragm spring damaged
during transaxle installation
Release fork and (or) bushings
damaged
Replace fork and (or) bushings if worn or
damaged
Clutch cable binding or routed
incorrectly
Check and correct cable routing
Self-adjuster in cable not functioning
properly, resulting in excess cable slack
Pull on cable conduit at transaxle (as if
disconnecting cable) to check adjuster
operation
Clutch pedal travel restricted Verify clutch pedal can travel all the way
to the downstop on the bracket
SERVICE DIAGNOSISCLUTCH PEDAL NOISE
CLUTCH PEDAL MAKES
REPEATED POP NOISE
IN THE FIRST INCH OF
TRAVEL
Self-adjusting mechanism in cable
defective (LHD Applications)
Replace clutch cable (LHD Applications)
CLUTCH PEDAL
SQUEAKS WHEN
DEPRESSED TO FLOOR
Pedal bushings worn out or inadequate
lubrication
Replace or lubricate bushings
Clutch pedal assist spring fittings worn
out
Replace assist spring fittings
Clutch release shaft bushings in the
bellhousing are worn out
Replace release shaft and bushings
DRIVE PLATE MISALIGNMENT
Common causes of mi sal i gnment are:
Heat warpi ng
Mounti ng dri ve pl ate on a di rty crankshaft
fl ange
I ncorrect bol t ti ghteni ng
I mproper seati ng on the crankshaft shoul der
Loose crankshaft bol ts
Cl ean the crankshaft fl ange before mounti ng the
dri ve pl ate. Di rt and grease on the fl ange surface
may mi sal i gn the fl ywheel , causi ng excessi ve runout.
Use new bol ts when mounti ng dri ve pl ate to crank-
shaft. Ti ghten dri ve pl ate bol ts to speci fi ed torque
onl y. Over-ti ghteni ng can di stort the dri ve pl ate hub
causi ng excessi ve runout.
NS/GS CLUTCH 6 - 7
CLUTCH COVER AND DISC RUNOUT
Check condi ti on of the cl utch cover before i nstal l a-
ti on. A warped cover or di aphragm spri ng wi l l cause
grab and/or i ncompl ete rel ease or engagement. Use
care when handl i ng the cl utch assembl y. I mpact can
di stort the cover, di aphragm spri ng, and rel ease fi n-
gers.
CLUTCH CHATTER COMPLAINTS
For al l cl utch chatter compl ai nts, do the fol l owi ng:
(1) Check for l oose, mi sal i gned, or broken engi ne
and transmi ssi on mounts. I f present, they shoul d be
corrected at thi s ti me. Test vehi cl e for chatter. I f
chatter i s gone, there i s no need to go any further. I f
chatter persi sts:
(2) Check to see i f cl utch cabl e routi ng i s correct
and operates smoothl y (LHD appl i cati ons).
(3) Check for l oose connecti ons i n dri vetrai n. Cor-
rect any probl ems and determi ne i f cl utch chatter
compl ai nts have been sati sfi ed. I f not:
(4) Remove transaxl e. See Group 21, Manual Tran-
saxl e for procedure.
(5) Check to see i f the rel ease beari ng i s sti cky or
bi ndi ng. Repl ace beari ng, i f needed.
(6) Check l i nkage for excessi ve wear on the pi vot
shaft, fork, and bushi ngs. Repl ace al l worn parts.
(7) Check cl utch assembl y for contami nati on (di rt,
oi l ). Repl ace cl utch assembl y, i f requi red.
(8) Check to see i f the cl utch di sc hub spl i nes are
damaged. Repl ace wi th new cl utch assembl y, i f nec-
essary.
(9) Check i nput shaft spl i nes for damage. Repl ace,
i f necessary.
(10) Check for uneven wear on cl utch fi ngers.
(11) Check for broken cl utch cover di aphragm
spri ng fi ngers. Repl ace wi th new cl utch assembl y, i f
necessary.
CLASHINTOREVERSE COMPLAINTS
(1) Depress cl utch pedal to fl oor and hol d. After
three seconds, shi ft to reverse. I f cl ash i s present,
cl utch has excessi ve spi n ti me.
NOTE: Verify that nothing is obstructing pedal
travel. Floormats or other articles located under-
neath the clutch pedal could prevent the clutch
from disengaging fully.
(2) Remove transaxl e. See Group 21, Manual Tran-
saxl e for procedure.
(3) Check the i nput shaft spl i ne, cl utch di sc
spl i nes, and rel ease beari ng for dry rust. I f present,
cl ean rust off and appl y a l i ght coat of beari ng grease
to the i nput shaft spl i nes. Appl y grease on the i nput
shaft spl i nes onl y where the cl utch di sc sl i des. Veri fy
that the cl utch di sc sl i des freel y al ong the i nput shaft
spl i ne.
(4) Check to see i f the cl utch di sc hub spl i nes are
damaged, and repl ace wi th new cl utch assembl y i f
requi red.
(5) Check the i nput shaft for damaged spl i nes.
Repl ace as necessary.
(6) Check for broken cl utch cover di aphragm
spri ng fi ngers.
(7) I nstal l cl utch assembl y and transaxl e.
CLUTCH CABLE SYSTEM LHD
REMOVAL
(1) Hoi st vehi cl e
(2) Usi ng a pai r of pl i ers, grasp end of cl utch cabl e
and pul l downward.
(3) Remove cl utch cabl e retai ni ng cl i p from cl utch
rel ease l ever (Fi g. 9).
(4) Gui de cabl e through sl ot i n transaxl e and di s-
connect (Fi g. 10).
(5) Unsnap cabl e from the cabl e gui de l ocated at
the l eft shock tower (Fi g. 10).
(6) I nsi de the vehi cl e, remove the dri ver si de l ower
dash cover and steel support pl ate. Thi s provi des
access to the top of the cl utch pedal .
(7) Di sconnect cl utch cabl e upstop/spacer wi th
cabl e strand from cl utch pedal (Fi g. 11) (Fi g. 12).
Fig. 9 Clutch Cable Retaining Clip LHD
6 - 8 CLUTCH NS/GS
NOTE: Depressing the clutch pedal to the floor pro-
vides access to the clutch cable strand. Disconnect
the cable upstop/spacer from the pedal pivot pin by
removing the retaining clip at the top of the clutch
pedal. Wedge a flat blade pry tool in the clip slot to
remove the clip. Remove the clutch pedal upstop/
spacer from the pedal by wedging a flat blade pry
tool between the spacer and pedal. It may be nec-
essary to push the steel support bracket supporting
the electrical junction block slightly to the left for
clearance to remove the upstop/spacer from the
pedal. Push the cable end fitting out of upstop/
spacer.
CAUTION: Use caution if lifting the clutch pedal
once the clutch pedal/upstop spacer has been
removed. The clutch pedal assist spring provides
enough pedal force to cause an injury. Also, on 2.5L
Turbo Diesel vehicles, lifting the clutch pedal with
the upstop/spacer removed may bend the cruise
control cutout switch bracket located near the top
of the clutch pedal. This will result in non-opera-
tional cruise control.
CAUTION: Do not pull on the clutch cable to
remove it from the dash panel. Damage to the cable
self-adjuster may occur.
NOTE: It may be helpful to remove the battery and
clutch cable guide from the left shock tower to
improve access to the clutch cable dash panel
grommet.
Fig. 10 Clutch Cable Routing LHD Fig. 11 Clutch Cable Retaining (Upstop) Clip LHD
Fig. 12 Upstop/Spacer LHD
NS/GS CLUTCH 6 - 9
(8) Use a sl i ght twi sti ng moti on whi l e graspi ng the
grommet and body to remove the cabl e from the dash
panel and cl utch bracket.
INSTALLATION
(1) Usi ng a sl i ght twi sti ng moti on, i nsert the sel f-
adjuster mechani sm end of the cl utch cabl e through
the dash panel hol e and i nto the bracket.
NOTE: It may be helpful to lubricate the dash panel
grommet using Mopar Door-Ease or equivalent to
aid installation.
(2) Seat the cyl i ndri cal part of the cabl e grommet
i n the dash panel . Be sure the sel fadjuster i s fi rml y
seated agai nst the cl utch bracket to ensure proper
adjuster mechani sm functi on.
(3) Connect the cl utch cabl e to the upstop/spacer.
(4) Connect the upstop/spacer to the cl utch pedal .
(5) Repl ace the upstop/spacer retai ner cl i p.
(6) Li ft the cl utch pedal and perform the Adjuster
Mechani sm Functi on Check before fi ni shi ng i nstal l a-
ti on.
NOTE: If the adjuster mechanism does not function
properly, the most likely cause is that the cable is
not properly seated in the bracket.
ADJUSTER MECHANISM FUNCTION CHECK LHD
(1) Wi th sl i ght pressure, pul l the cl utch rel ease
l ever end of the cabl e to draw the cabl e taut. Push
the cl utch cabl e housi ng toward the dash panel (Wi th
l ess than 20 l bs. of effort, the cabl e housi ng shoul d
move 30-50mm.). Thi s i ndi cates proper adjuster
mechani sm functi on. I f the cabl e does not adjust,
determi ne i f the mechani sm i s properl y seated on the
bracket.
(2) I f the adjust mechani sm functi ons properl y,
route cabl e to the transaxl e. I nstal l battery and cabl e
gui de.
(3) Snap cabl e i nto cabl e gui de l ocated at the l eft
shock tower.
(4) I nsert cabl e i nto transaxl e and through cl utch
rel ease l ever. Ensure the cabl e i s routed through the
smal l er hol e i n the transaxl e deck (Fi g. 10).
(5) Pul l down on cabl e and i nsert cabl e retai ni ng
cl i p onto cl utch cabl e end.
(6) Check cl utch pedal posi ti on swi tch operati on.
posi ti on (Fi g. 13).
REMOVAL
(1) Di sconnect el ectri cal harness to swi tch connec-
tor.
(2) Depress wi ng tabs on swi tch and push swi tch
out of mounti ng bracket. Then sl i de wi res through
sl ot i n bracket.
INSTALLATION
(1) Sl i de swi tch wi res through sl ot i n swi tch
bracket.
(2) Li ne up swi tch tab wi th sl ot i n swi tch bracket
and push swi tch i nto posi ti on. Do not pul l on the
swi tch wi res to seat swi tch i nto bracket, swi tch dam-
age may occur.
(3) Attach swi tch wi ri ng harness to vehi cl e wi ri ng
harness. Attach swi tch panel to the dash panel
bracket (Fi g. 13).
(4) After i nstal l ati on, the swi tch must be checked
for proper operati on. Refer to Di agnosi s and Testi ng
secti on for proper testi ng procedures.
Fig. 13 Clutch Pedal Position Switch and
Components (LHD Shown)
6 - 10 CLUTCH NS/GS
HYDRAULIC CLUTCH LINKAGE SYSTEM RHD
CAUTION: Do not actuate the master cylinder or
step on the clutch pedal before the quick connect
coupling is joined or an over pressure condition
could result in damage to the master cylinder, the
quick connect coupling, or the dash panel.
NOTE: The hydraulic clutch linkage system is pre-
filled by the supplier who warrants the system to be
free of air, contamination, and leaks. No routine
maintenance is required. Except for the self-retain-
ing snap-on master cylinder pushrod bushing, the
hydraulic system is serviced only as a complete
assembly and individual components cannot be
overhauled or replaced.
REMOVAL
1. Di sconnect the qui ck connect coupl i ng to faci l i -
tate the removal of the master cyl i nder assembl y and
sl ave cyl i nder assembl y separatel y (Fi g. 14). Refer to
the removal and i nstal l ati on procedure i n thi s secti on
for detai l ed i nstructi ons on di sconnecti ng and con-
necti ng the qui ck connect coupl i ng.
2. Remove the master cyl i nder assembl y (Fi g. 15).
Refer to the master cyl i nder removal and i nstal l ati on
procedure i n thi s secti on for detai l ed i nstructi ons on
removal of the master cyl i nder assembl y.
3. Remove the sl ave cyl i nder assembl y. Refer to
the sl ave cyl i nder removal and i nstal l ati on procedure
i n thi s secti on for detai l ed i nstructi ons on removal
and i nstal l ati on of the sl ave cyl i nder.
INSTALLATION
1. For i nstal l ati on of the hydraul i c cl utch l i nkage
system, reverse the above procedure.
Fig. 14 Hydraulic Clutch Linkage System RHD
Fig. 15 Self-Retaining Snap-on Bushing RHD
NS/GS CLUTCH 6 - 11
QUICK CONNECT COUPLING RHD
CAUTION: Do not actuate the master cylinder or
step on the clutch pedal before the quick connect
coupling is joined, or an over pressure condition
could result in damage to the master cylinder, the
quick connect coupling, or the dash panel.
REMOVAL
1. Di sconnect the qui ck connect coupl i ng by l i ghtl y
pushi ng down on the bl ack rel ease col l ar on the mal e
si de of the qui ck connect coupl i ng whi l e separati ng i t
from the femal e si de of the qui ck connect coupl i ng
(Fi g. 14).
INSTALLATION
1. Connect the mal e si de of the qui ck connect cou-
pl i ng (part of the master cyl i nder assembl y) by hol d-
i ng the cl utch tube at the rear and i nserti ng i t i nto
the femal e si de of the qui ck connect coupl i ng (part of
the sl ave cyl i nder assembl y) unti l an audi bl e cl i ck i s
heard (Fi g. 14). Do not push on the black release
collar on the male side of the quick connect
coupling while inserting it into the female side
of the quick connect coupling.
2. Confi rm the connecti on by pul l i ng fi rml y on the
cl utch tube.
MASTER CYLINDER SYSTEM RHD
REMOVAL
(1) Di sconnect the qui ck connect coupl i ng. Refer to
the Qui ck Connect Coupl i ng removal and i nstal l a-
ti on procedure i n thi s secti on.
(2) Remove the master cyl i nder pushrod from the
cl utch pedal pi n by pryi ng between the sel f-retai ni ng
snap-on bushi ng, l ocated i n the master cyl i nder
pushrod, and the cl utch pedal pi n (Fi g. 15).
(3) Di sconnect the hydraul i c l i ne from the wel d
stud cl i ps (Fi g. 14).
(4) Remove the rubber grommet at the master cyl -
i nder pass through i n the dash panel (Fi g. 16).
(5) Remove the master cyl i nder assembl y from the
engi ne compartment by rotati ng i t cl ockwi se from the
12 ocl ock l ock posi ti on to the 2 ocl ock unl ock posi -
ti on and pul l i ng the master cyl i nder out ti l ted 20
degrees down. NOTE: A Twist and Lock type
mechanism is used to secure the master cylin-
der to the clutch pedal bracket which is
attached to the dash panel.
INSTALLATION
(1) Posi ti on the master cyl i nder assembl y to the
cl utch pedal bracket by ti l ti ng i t 20 degrees upward
and at the 2 ocl ock unl ocked posi ti on.
(2) Rotate the master cyl i nder countercl ockwi se to
the 12 ocl ock l ocked posi ti on.
(3) I nstal l the rubber grommet i nto the dash panel
at the master cyl i nder pass through (Fi g. 16).
(4) Connect the hydraul i c l i ne to the wel d stud
cl i ps i n the engi ne compartment (Fi g. 14).
(5) Connect the qui ck connect coupl i ng. Refer to
(6) I nstal l the sel f-retai ni ng snap-on bushi ng i nto
the master cyl i nder pushrod, i f necessary.
(7) I nstal l the master cyl i nder pushrod wi th sel f-
retai ni ng snap-on bushi ng onto the cl utch pedal pi n
by pressi ng i t onto the cl utch pedal pi n unti l seats i n
the groove of the cl utch pedal pi n.
SLAVE CYLINDER ASSEMBLY RHD
REMOVAL
1. Di sconnect the qui ck connect coupl i ng. Refer to
2. Remove the nut and washer assembl i es (2)
retai ni ng the sl ave cyl i nder and mounti ng bracket
assembl y to the transaxl e (Fi g. 14).
3. Remove the sl ave cyl i nder assembl y from the
transaxl e.
Fig. 16 Clutch Master Cylinder RHD
6 - 12 CLUTCH NS/GS
INSTALLATION
1. Posi ti on the sl ave cyl i nder assembl y to the tran-
saxl e deck and secure wi th the nut and washer
assembl i es (2) and ti ghten to speci fi cati ons (Fi g. 14).
2. Make sure the sl ave cyl i nder pushrod i s prop-
erl y seated i n the cup end of the cl utch rel ease l ever.
3. Connect the qui ck connect coupl i ng. Refer to the
Qui ck Connect Coupl i ng removal and i nstal l ati on
procedure i n thi s secti on.
MODULAR CLUTCH ASSEMBLY (2. 0L AND 2. 4L
GASOLINE)
The transaxl e must be removed to servi ce the mod-
ul ar cl utch assembl y and components (Fi g. 17). Refer
to Group 21 for the A-558 Manual Transaxl e
removal procedure.
CLUTCH ASSEMBLY (2. 5L DIESEL)
The transaxl e must be removed to servi ce the
cl utch di sc assembl y and components.
REMOVAL
(1) Remove the transaxl e, refer to Group 21, Tran-
saxl e.
(2) I nstal l uni versal cl utch al i gnment tool i nto the
cl utch assembl y (thi s wi l l prevent the cl utch from
i nadvertentl y bei ng dropped).
(3) To avoi d di storti on of the pressure pl ate,
remove the cl utch pressure pl ate bol ts a few turns at
a ti me. Use a cri sscross pattern unti l al l bol ts are
l oosened.
(4) Careful l y remove the cl utch pressure pl ate and
di sc (Fi g. 18).
To servi ce the fl ywheel , refer to Group 9, Engi ne.
INSPECTION
I nspect for oi l l eakage through engi ne rear mai n
beari ng oi l seal and transaxl e i nput shaft seal . I f
l eakage i s noted, i t shoul d be corrected at thi s ti me.
The fri cti on faces of the fl ywheel and pressure
pl ate shoul d not have:
Excessi ve di scol orati on
Burned areas
Smal l cracks
Deep grooves
Ri dges
Repl ace parts as requi red.
CAUTION: Do not polish flywheel to a mirror like
surface. Clean the flywheel face with medium sand-
paper (80-160 grade), then wipe the surface with
mineral spirits. If the surface is severely scored,
heat checked, or warped, replace the flywheel.
CAUTION: Do not flat-machine the flywheel face.
The surface profile is slightly tapered and has a
0.30 mm step.
The di sc assembl y shoul d be handl ed wi thout
touchi ng the faci ngs. Repl ace di sc i f the faci ngs show
evi dence of grease or oi l soakage, or wear to wi thi n
l ess than .38 mm (.015 i nch) of the ri vet heads. The
spl i nes on the di sc hub and transaxl e i nput shaft
shoul d be a snug fi t wi thout si gns of excessi ve wear.
Metal l i c porti ons of di sc assembl y shoul d be dry and
cl ean, and not been di scol ored from excessi ve heat.
Each of the arched spri ngs between the faci ngs
shoul d not be broken and al l ri vets shoul d be ti ght.
Wi pe the fri cti on surface of the pressure pl ate wi th
mi neral spi ri ts.
Usi ng a strai ght edge, check cl utch cover (pressure
pl ate) for fl atness. The cl utch cover (pressure pl ate)
Fig. 17 Modular Clutch Assembly 2.0L and 2.4L
Fig. 18 Clutch Disc, Cover and Pressure Plate
NS/GS CLUTCH 6 - 13
fri cti on area shoul d be sl i ghtl y concave, wi th the
i nner di ameter 0.02 mm to 0.1 mm (.0008 i n. to .0039
i n.) bel ow the outer di ameter. I t shoul d al so be free
from di scol orati on, burned areas, cracks, grooves, or
ri dges.
Usi ng a surface pl ate, test cover for fl atness. Al l
secti ons around attachi ng bol t hol es shoul d be i n con-
tact wi th surface pl ate wi thi n .015 i nch.
The cover shoul d be a snug fi t on fl ywheel dowel s.
I f the cl utch assembl y does not meet these requi re-
ments, i t shoul d be repl aced.
INSTALLATION
(1) Posi ti on the cl utch and pressure pl ate onto the
fl ywheel .
(2) I nsert the uni versal cl utch al i gnment tool i nto
the cl utch di sc.
(3) To avoi d di storti on of the pressure pl ate, bol ts
shoul d be ti ghtened a few turns at a ti me (Fi g. 19).
Use a cri sscross pattern unti l al l bol ts are seated.
Ti ghten pressure pl ate bol ts to 27 Nm (20 ft. l bs.).
(4) Remove the uni versal cl utch al i gnment tool .
(5) I nstal l the transaxl e, refer to Group 21, Tran-
saxl e.
(6) Fi l l transaxl e to the proper l evel wi th the spec-
i fi ed l ubri cant.
(7) Whi l e the vehi cl e i s el evated sl i ghtl y, run the
transaxl e through al l the forward gears. Appl y
brakes and shi ft i nto reverse. Run the transaxl e
through reverse gear.
(8) Check the transaxl e for l eaks and recheck the
l evel of the transaxl e l ubri cant.
CLUTCH RELEASE BEARING AND FORK
Remove the transaxl e from the vehi cl e. See Group
21, for removal and i nstal l ati on procedures.
REMOVAL
(1) Remove cl utch rel ease shaft E-cl i p (Fi g. 20).
(2) Remove the cl utch rel ease shaft and then sl i de
the fork and beari ng assembl y off the beari ng pi l ot
(Fi g. 21).
Fig. 19 2.5 Diesel Clutch Assembly
Fig. 20 E-clip at Clutch Release Lever Shaft
Fig. 21 Clutch Release Shaft
6 - 14 CLUTCH NS/GS
(3) Remove the fork from the beari ng thrust pl ate
(Fi g. 22).
(4) Exami ne the condi ti on of the beari ng. I t i s pre-
l ubri cated and seal ed and shoul d not be i mmersed i n
oi l or sol vent.
(5) The beari ng shoul d turn smoothl y when hel d i n
the hand under a l i ght thrust l oad. A l i ght drag
caused by the l ubri cant fi l l i s normal . I f the beari ng
i s noi sy, rough, or dry, repl ace the compl ete beari ng
assembl y wi th a new beari ng.
(6) The beari ng has a pl asti c sl eeve pre-l ubri cated
at assembl y. Wi pe out the ol d grease. Refi l l the sl eeve
cavi ti es and coat the i nner surface wi th mul ti purpose
grease. I f the l i ner i s cracked or worn, repl ace the
beari ng assembl y.
(7) Check the condi ti on of the spri ng cl i ps. I f the
cl i ps are broken or di storted, repl ace the beari ng
assembl y.
INSTALLATION
(1) Before assembl i ng the fork, l ubri cate the
rounded thrust pads and the spri ng cl i p cavi ti es wi th
mul ti purpose grease.
(2) Assembl e the fork to the beari ng by sl i di ng the
thrust pads under the spri ng cl i ps. Be careful to
avoi d di storti ng the spri ng cl i ps. These cl i ps prevent
the beari ng thrust pl ate from rotati ng wi th the bear-
i ng.
(3) Sl i de the beari ng and fork assembl y onto the
i nput shaft beari ng retai ner.
(4) Posi ti on the rel ease shaft bushi ngs i n the hous-
i ng and i nstal l the rel ease shaft. A smal l amount of
beari ng grease between the rel ease shaft bushi ng
and the shaft i s benefi ci al but not requi red. I nstal l
the retai ner cl i p i n the shaft groove near the l arge
bushi ng.
(5) I nstal l the rel ease l ever and retai ni ng cl i p on
the outer end of the rel ease shaft.
CLUTCH CONTAMINATION
Fl ui d contami nati on i s a frequent cause of cl utch
mal functi ons. Oi l , grease, water, or other fl ui ds on
the cl utch contact surfaces wi l l cause faul ty opera-
ti on.
Duri ng i nspecti on, note i f any components are con-
tami nated. Look for evi dence of oi l , grease, or water/
road spl ash on cl utch components.
OIL CONTAMINATION
Oi l contami nati on i ndi cates a l eak at the rear mai n
seal and/or transaxl e i nput shaft. Oi l l eaks produce a
resi due of oi l on the transaxl e housi ng i nteri or, cl utch
cover and fl ywheel . Heat bui l dup caused by sl i ppage
can bake the oi l resi due onto the components. Thi s
gl aze-l i ke resi due ranges i n col or from amber to
bl ack.
GREASE CONTAMINATION
Grease contami nati on i s usual l y a product of over-
l ubri cati on. Duri ng cl utch servi ce, appl y onl y a smal l
amount of grease to the i nput shaft spl i nes. Excess
grease may be thrown off duri ng operati on, contami -
nati ng the di sc.
ROAD SPLASH/WATER CONTAMINATION
Road spl ash contami nati on i s usual l y caused by
dri vi ng the vehi cl e through deep water puddl es.
Water can be forced i nto the cl utch housi ng, causi ng
cl utch components to become contami nated. Faci ng of
di sc wi l l absorb moi sture and bond to the fl ywheel
and/or, pressure pl ate, i f vehi cl e i s al l owed to stand
for some ti me before use. I f thi s condi ti on occurs,
repl acement of cl utch assembl y may be requi red.
Dri ve the vehi cl e unti l normal cl utch operati ng tem-
perature has been obtai ned. Thi s wi l l dry off di sc
assembl y, pressure pl ate, and fl ywheel .
CLEANING PRECAUTIONS
Condensati on from steam vapors tend to accumu-
l ate on the i nternal cl utch mechani sm when the vehi -
cl e i s steam cl eaned. Faci ng of di sc wi l l absorb
moi sture and wi l l bond to fl ywheel and/or pressure
pl ate, i f vehi cl e i s al l owed to stand for some ti me
before use. I f thi s condi ti on occurs, i t may requi re
repl acement of cl utch assembl y. After cl eani ng, dri ve
the vehi cl e to i ts normal cl utch operati ng tempera-
ture. Thi s wi l l dry off di sc assembl y, pressure pl ate,
and fl ywheel .
Fig. 22 Clutch Release Fork
NS/GS CLUTCH 6 - 15
ADJ USTMENTS
CLUTCH CABLE LHD
The manual transaxl e cl utch rel ease system has a
uni que sel f-adjusti ng mechani sm to compensate for
cl utch di sc wear. Thi s adjuster mechani sm i s l ocated
wi thi n the cl utch cabl e assembl y. The prel oad spri ng
mai ntai ns tensi on on the cabl e. Thi s tensi on keeps
the cl utch rel ease beari ng conti nuousl y l oaded
agai nst the fi ngers of the cl utch cover assembl y.
ADJ USTER MECHANISM FUNCTION CHECK
LHD
(1) Wi th sl i ght pressure, pul l the cl utch rel ease
l ever end of the cabl e to draw the cabl e taut. Push
the cl utch cabl e housi ng toward the dash panel (Wi th
l ess than 20 l bs. of effort, the cabl e housi ng shoul d
move 30-50mm.). Thi s i ndi cates proper adjuster
mechani sm functi on. I f the cabl e does not adjust,
determi ne i f the mechani sm i s properl y seated on the
bracket.
(2) I f the adjust mechani sm functi ons properl y,
route cabl e to the transaxl e.
(3) I nsert cabl e i nto transaxl e and through cl utch
rel ease l ever. Ensure the cabl e i s routed through the
smal l er hol e i n the transaxl e deck (Fi g. 10).
(4) Pul l down on cabl e and i nsert cabl e retai ni ng
cl i p onto cl utch cabl e end.
(5) Check cl utch pedal posi ti on swi tch operati on.
posi ti on.
SPECIFICATIONS
CLUTCH TIGHTENING REFERENCE
2.0/2.4 LITER GASOLINE ENGINE
DESCRIPTION TORQUE
Dri ve Pl ate Bol ts . . . . . . . . . . . . 95 Nm (70 ft. l bs.)
Lower Trans. Cover . . . . . . . . . 12 Nm (105 i n. l bs.)
Modul ar Cl utch Bol ts . . . . . . . . . 74 Nm (55 ft. l bs.)
Upper Trans. Cover . . . . . . . . . 12 Nm (105 i n. l bs.)
2.5 LITER DIESEL ENGINE
DESCRIPTION TORQUE
Fl ywheel Bol ts . . . . . . . . . . . . . . 95 Nm (70 ft. l bs.)
Lower Trans. Cover . . . . . . . . . 12 Nm (105 i n. l bs.)
Cl utch Pressure Pl ate Bol ts . . . . 27 Nm (20 ft. l bs.)
Upper Trans. Cover . . . . . . . . . 12 Nm (105 i n. l bs.)
6 - 16 CLUTCH NS/GS
COOLING SYSTEM
CONTENTS
page page
GENERAL INFORMATION
ACCESSORY DRIVE BELTS . . . . . . . . . . . . . . . . 1
AUTOMATIC TRANSMISSION OIL COOLER
2.4L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
COOLANT RECOVERY SYSTEM (CRS) . . . . . . . 3
COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 2
ENGINE BLOCK HEATER . . . . . . . . . . . . . . . . . . 5
ENGINE THERMOSTAT . . . . . . . . . . . . . . . . . . . . 3
RADIATOR PRESSURE CAP . . . . . . . . . . . . . . . . 4
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
WATER PUMPS . . . . . . . . . . . . . . . . . . . . . . . . . 3
COOLANT PERFORMANCE . . . . . . . . . . . . . . . . . 6
RADIATOR HOSES AND CLAMPS . . . . . . . . . . . 6
WATER PIPES3.0L ENGINE . . . . . . . . . . . . . . 6
WATER PUMP3.3/3.8L ENGINES . . . . . . . . . . 7
WATER PUMP2.4L ENGINE . . . . . . . . . . . . . . 6
WATER PUMP3.0L ENGINE . . . . . . . . . . . . . . 6
ACCESSORY DRIVE BELT . . . . . . . . . . . . . . . . . . 7
COOLING SYSTEM DIAGNOSIS . . . . . . . . . . . . . 8
DEAERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 16
ELECTRIC FAN MOTOR TEST . . . . . . . . . . . . . . 14
LOW COOLANT LEVEL AERATION . . . . . . . . . . 15
PRESSURE TESTING RADIATOR CAP . . . . . . . 15
RADIATOR CAP TO FILLER NECK SEAL
PRESSURE RELIEF CHECK . . . . . . . . . . . . . . 15
RADIATOR COOLANT FLOW TEST . . . . . . . . . . 14
RADIATOR FAN CONTROL . . . . . . . . . . . . . . . . 14
TEMPERATURE GAUGE INDICATION . . . . . . . . 16
TESTING COOLING SYSTEM FOR LEAKS . . . . 14
SERVICE PROCEDURES
COOLANT LEVEL CHECKROUTINE . . . . . . . . 16
COOLANT LEVEL SERVICE . . . . . . . . . . . . . . . . 16
COOLANTADDING ADDITIONAL . . . . . . . . . . 16
COOLING SYSTEMDRAINING. . . . . . . . . . . . 16
COOLING SYSTEMREFILLING . . . . . . . . . . . 16
ACCESSORY DRIVE BELTS2.4L . . . . . . . . . . 23
ACCESSORY DRIVE BELTS3.0L . . . . . . . . . . 24
ACCESSORY DRIVE BELT3.3/3.8L . . . . . . . . 24
ENGINE BLOCK HEATER . . . . . . . . . . . . . . . . . 23
FAN MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . 22
RADIATOR DRAINCOCK . . . . . . . . . . . . . . . . . . 21
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
THERMOSTAT2.4L ENGINE . . . . . . . . . . . . . 19
THERMOSTAT3.0L ENGINE . . . . . . . . . . . . . 20
THERMOSTAT3.3/3.8L ENGINES . . . . . . . . . 20
WATER PUMP INLET TUBE2.4L ENGINE . . . 17
WATER PUMP3.3/3.8L ENGINES . . . . . . . . . 19
WATER PUMP2.4L ENGINE . . . . . . . . . . . . 17
WATER PUMP3.0L ENGINE . . . . . . . . . . . . . 18
ACCESSORY DRIVE BELT . . . . . . . . . . . . . . . . . 25
CHEMICAL CLEANING . . . . . . . . . . . . . . . . . . . 25
COOLING SYSTEM CLEANING . . . . . . . . . . . . . 25
RADIATOR PRESSURE CAP . . . . . . . . . . . . . . . 25
REVERSE FLUSHING THE ENGINE . . . . . . . . . 25
REVERSE FLUSHING THE RADIATOR . . . . . . . 25
WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . 24
ADJUSTMENTS
BELT TENSION CHART . . . . . . . . . . . . . . . . . . . 26
BELT TENSION GAUGE METHOD . . . . . . . . . . . 26
PROPER BELT TENSION . . . . . . . . . . . . . . . . . 25
SPECIFICATIONS
COOLING SYSTEM CAPACITY . . . . . . . . . . . . . 26
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . 26
SPECIAL TOOLS
COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
GENERAL INFORMATION
ACCESSORY DRIVE BELTS
The accessory dri ve system uti l i zes two di fferent
styl e of dri ve bel ts. The conventi onal V-bel t and the
Pol y-V bel t are used to dri ve the generator, ai r con-
di ti oni ng compressor, power steeri ng pump and water
pump. Sati sfactory performance of these bel ts
depends on bel t condi ti on and proper bel t tensi on.
Bel t tensi oni ng shoul d be performed wi th the ai d of a
Burroughs gauge Speci al Tool C-4162. Because of
space l i mi tati ons i n the engi ne compartment, the use
of the gauge may be restri cted. Rai se the vehi cl e on a
hoi st and then remove the spl ash shi el d to gai n
access to the dri ve bel ts.
NS COOLING SYSTEM 7 - 1
COOLING SYSTEM
The cool i ng system has a radi ator, cool ant, el ectri c fan
motor, shroud, pressure cap, thermostat, cool ant reserve
system, transmi ssi on oi l cool er, a water pump to ci rcul ate
the cool ant, hoses, and cl amps to compl ete the ci rcui t.
When Engi ne i s col d: thermostat i s cl osed, cool -
i ng system has no fl ow through the radi ator. The
cool ant bypass fl ows through the engi ne onl y.
When Engi ne i s warm: thermostat i s open, cool i ng
system has bypass fl ow and cool ant fl ow through radi a-
tor.
I ts pri mary purpose i s to mai ntai n engi ne temper-
ature i n a range that wi l l provi de sati sfactory engi ne
performance and emi ssi on l evel s under al l expected
dri vi ng condi ti ons. I t al so provi des hot water (cool -
ant) for heater performance and cool i ng for automati c
transmi ssi on oi l . I t does thi s by transferri ng heat
from engi ne metal to cool ant, movi ng thi s heated
cool ant to the radi ator, and then transferri ng thi s
heat to the ambi ent ai r.
Cool ant fl ow ci rcui ts for 2.4L and 3.3/3.8L engi nes
are shown i n (Fi g. 1), and 3.0L engi ne cool ant rout-
i ng i s shown i n (Fi g. 2)
Fig. 1 Cooling System Operation 2.4L and 3.3/3.8L Engines
Fig. 2 Cooling System Operation 3.0L Engine
7 - 2 COOLING SYSTEM NS
COOLANT RECOVERY SYSTEM (CRS)
Thi s system works wi th the radi ator pressure cap
to use thermal expansi on and contracti on of the cool -
ant to keep the cool ant free of trapped ai r. Provi des a
conveni ent and safe method for checki ng cool ant
l evel and adjusti ng l evel at atmospheri c pressure
wi thout removi ng the radi ator pressure cap. I t al so
provi des some reserve cool ant to cover deaerati on
and evaporati on or boi l i ng l osses. Al l vehi cl es are
equi pped wi th thi s system and take vari ous shapes
and forms. (Fi g. 3) shows a typi cal system i n the typ-
i cal l ocati on.
See Cool ant Level Servi ce, and Deaerati on, and
Pressure Cap secti ons for operati on and servi ce.
AUTOMATIC TRANSMISSION OIL COOLER 2. 4L
Oi l cool er i s i nternal oi l to cool ant type, mounted
i n the radi ator l eft tank (Fi g. 4). Rubber oi l l i nes feed
the oi l cool er and the automati c transmi ssi on. Use
onl y approved transmi ssi on oi l cool er hose. Si nce
these are mol ded to fi t space avai l abl e, mol ded hoses
are recommended.
ENGINE THERMOSTAT
The engi ne cool i ng thermostats are a wax pel l et
dri ven, reverse poppet choke type. They are desi gned
to provi de the fastest warm up possi bl e by prevent-
i ng l eakage through them and to guarantee a mi ni -
mum engi ne operati ng temperature of 88 to 93C
(192 to 199F). They al so automati cal l y reach wi de
open so they do not restri ct fl ow to the radi ator as
temperature of the cool ant ri ses i n hot weather to
around 104C (220F). Above thi s temperature the
cool ant temperature i s control l ed by the fan, the
radi ator, and the ambi ent temperature, not the ther-
mostat.
WATER PUMPS
A qui ck test to tel l whether the pump i s worki ng i s
to see i f the heater warms properl y. A defecti ve pump
can not ci rcul ate heated cool ant through the l ong
heater hose. The water pump on all models can
be replaced without discharging the air condi-
tioning system.
COOLANT
The cool i ng system i s desi gned around the cool ant.
The cool ant must accept heat from engi ne metal , i n
the cyl i nder head area near the exhaust val ves. Cool -
ant then carri es thi s heat to the radi ator, where the
tube/fi n assembl i es of these components can gi ve i t
up to the ai r.
The use of al umi num cyl i nder heads, i ntake mani -
fol ds, and water pumps requi res speci al corrosi on
protecti on. Mopar Anti freeze or the equi val ent i s
recommended for best engi ne cool i ng wi thout corro-
si on, when mi xed onl y to a freeze poi nt of -37C
(-35F) to -59C (-50F). I f i t l oses col or or becomes
contami nated, drai n, fl ush, and repl ace wi th fresh
properl y mi xed sol uti on.
CAUTION: Do not use well water, or suspect water
supply in cooling system. A 50/50 ethylene glycol
and distilled water mix is recommended.
RADIATOR
The radi ators are cross-fl ow types (hori zontal
tubes) wi th desi gn features that provi de greater
strength al ong wi th suffi ci ent heat transfer capabi l i -
Fig. 3 Coolant Recovery System
Fig. 4 Automatic Transmission Oil Cooler
ti es to keep the engi ne sati sfactori l y cool ed (Fi g. 5),
(Fi g. 6), (Fi g. 7) and (Fi g. 8).
CAUTION: Plastic tanks, while stronger then brass
are subject to damage by impact, such as wrenches
etc., or by excessive torque on hose clamps.
I f the pl asti c tank i s damaged, repl ace the radi a-
tor.
RADIATOR PRESSURE CAP
The radi ator i s equi pped wi th a pressure cap that
rel eases excessi ve cool i ng system pressure; mai ntai n-
i ng a range of 97-124 kPa (14-18 psi ).
The cool i ng system wi l l operate at hi gher than
atmospheri c pressure. The hi gher pressure rai ses the
cool ant boi l i ng poi nt thus, al l owi ng i ncreased radi a-
tor cool i ng capaci ty.
There i s al so a vent val ve i n the center of the cap.
Thi s val ve al so opens when cool ant i s cool i ng and
contracti ng al l owi ng cool ant to return to radi ator
from cool ant reserve system tank by vacuum through
connecti ng hose. If valve is stuck shut, or the
coolant recovery hose is pinched, the radiator
hoses will be collapsed on cool down. Clean the
vent valve (Fig. 9) and inspect coolant recovery
hose routing, to ensure proper sealing when
boiling point is reached.
The gasket i n the cap seal s the fi l l er neck, so that
vacuum can be mai ntai ned, al l owi ng cool ant to be
drawn back i nto the radi ator from the reserve tank.
Fig. 5 Cooling Module2.4L
Fig. 6 Cooling ModuleTrailer Tow (With Rear A/C)
If the gasket is dirty or damaged, a vacuum
may not be achieved, resulting is loss of coolant
and eventual overheating due to low coolant
level in radiator and engine.
ENGINE BLOCK HEATER
The engi ne bl ock heater i s avai l abl e as an opti onal
accessory on al l model s. The heater i s operated by
ordi nary house current (110 Vol t A.C.) through a
power cord l ocated behi nd the radi ator gri l l e. Thi s
provi des easi er engi ne starti ng and faster warm-up
when vehi cl e i s operated i n areas havi ng extremel y
l ow temperatures. The heater i s mounted i n a core
hol e (i n pl ace of a core hol e pl ug) i n the engi ne bl ock,
wi th the heati ng el ement i mmersed i n cool ant.
Fig. 7 Cooling Module3.0L (Front A/C Only)
Fig. 8 Cooling Module3.0/3.3/3.8L (With Rear A/C)
Fig. 9 Radiator Pressure Cap Filler Neck
WATER PIPES 3. 0L ENGINE
The 3.0L engi ne uses metal pi pi ng beyond the
l ower radi ator hose to route (sucti on) cool ant to the
water pump, whi ch i s l ocated i n the V of the cyl i nder
banks (Fi g. 10).
These pi pes are provi ded wi th i nl et ni ppl es for
thermostat bypass and heater return cool ant hoses,
and brackets for ri gi d engi ne attachment. The pi pes
empl oy O-ri ngs for seal i ng at thei r i nterconnecti on
and to the water pump (Fi g. 10).
COOLANT PERFORMANCE
Performance i s measurabl e. For heat transfer pure
water excel s (Formul a = 1 btu per mi nute for each
degree of temperature ri se for each pound of water).
Thi s formul a i s al tered when necessary addi ti ves to
control boi l i ng, freezi ng, and corrosi on are added as
fol l ows:
Pure Water (1 btu) boi l s at 100C (212F) and
freezes at 0C (32F)
100 percent Gl ycol (.7 btu) can cause a hot
engi ne and detonati on and wi l l l ower the freeze poi nt
to -22C (-8F).
50/50 Gl ycol and Water (.82 btu) i s the recom-
mended combi nati on that provi des a freeze poi nt of
-37C (-35F). The radi ator, water pump, engi ne
water jacket, radi ator pressure cap, thermostat, tem-
perature gauge, sendi ng uni t and heater are al l
desi gned for 50/50 gl ycol .
Where requi red, a 56 percent gl ycol and 44 percent
water mi xture wi l l provi de a freeze poi nt of -59C
(-50F).
CAUTION: Richer mixtures cannot be measured
with field equipment. This can lead to problems
associated with 100 percent glycol.
RADIATOR HOSES AND CLAMPS
WARNING: IF VEHICLE HAS BEEN RUN
RECENTLY, WAIT 15 MINUTES BEFORE WORKING
ON VEHICLE. RELIEVE PRESSURE BY PLACING A
SHOP TOWEL OVER THE CAP AND WITHOUT
PUSHING DOWN ROTATE IT COUNTERCLOCKWISE
TO THE FIRST STOP. ALLOW FLUIDS AND STEAM
TO ESCAPE THROUGH THE OVERFLOW TUBE.
THIS WILL RELIEVE SYSTEM PRESSURE
The hoses are removed by usi ng constant tensi on
cl amp pl i ers to compress the hose cl amp.
A hardened, cracked, swol l en or restri cted hose
shoul d be repl aced. Do not damage radi ator i nl et and
outl et when l ooseni ng hoses.
Radi ator hoses shoul d be routed wi thout any ki nks
and i ndexed as desi gned. The use of mol ded hoses i s
recommended.
Spri ng type hose cl amps are used i n al l appl i ca-
ti ons. I f repl acement i s necessary repl ace wi th the
ori gi nal MOPAR equi pment spri ng type cl amp.
WATER PUMP 2. 4L ENGINE
The water pump has a di ecast al umi num body and
housi ng wi th a stamped steel i mpel l er. The water
pump bol ts di rectl y to the bl ock. Cyl i nder bl ock to
water pump seal i ng i s provi ded by a rubber O-ri ng.
The water pump i s dri ven by the ti mi ng bel t. Refer
to Ti mi ng Bel t i n Group 9, Engi ne for component
removal provi di ng access to water pump.
The pump bol ts di rectl y to the engi ne bl ock, usi ng
a gasket for pump to bl ock seal i ng (Fi g. 11). The
pump i s servi ced as a uni t.
The water pump i s dri ven by the ti mi ng bel t. See
Ti mi ng Bel t i n Group 9, Engi ne for component
removal provi di ng access to water pump.
Fig. 10 Engine Inlet Coolant Pipes 3.0L Engine
WATER PUMP 3. 3/3. 8L ENGINES
The pump has a di e cast al umi num body and a
stamped steel i mpel l er. I t bol ts di rectl y to the chai n
case cover, usi ng an O-ri ng for seal i ng. I t i s dri ven by
the back surface of the Pol y-V Dri ve Bel t.
Fig. 11 Water Pump3.0L Engine
ACCESSORY DRIVE BELT
CONDITION POSSIBLE CAUSES CORRECTIONS
INSUFFICIENT ACCESSORY
OUTPUT DUE TO BELT SLIPPAGE
1. Belt too loose 1. Adjust belt tension (4 cyl. engine).
Replace belt (6 cyl. engine)
2. Belt excessively glazed or worn 2. Replace and tighten as specified
BELT SQUEAL WHEN
ACCELERATING ENGINE
1. Belts too loose 1. Adjust belt tension (4 cyl. engine).
2. Belt glazed 2. Replace belts
BELT SQUEAK AT IDLE 1. Belts too loose 1. Adjust belt tension (4 cyl. engine).
2. Dirt or paint imbedded in belt 2. Replace belt
3. Non-uniform belt 3. Replace belt
4. Misaligned pulleys 4. Align accessories
5. Non-uniform groove or eccentric
pulley
5. Replace pulley
BELT ROLLED OVER IN GROOVE
OR BELT JUMPS OFF
1. Broken cord in belt 1. Replace belt
2. Belt too loose, or too tight 2. Adjust belt tension (4 cyl. engine).
3. Misaligned pulleys 3. Align accessories
4. Non-uniform groove or eccentric
pulley
4. Replace pulley
COOLING SYSTEM DIAGNOSIS
CONDITION - AND CHECKS DIAGNOSIS
Inadequate Air Conditioning Performance - Cooling System Suspected
(1) Check for plugged air side of condenser and
radiator front and rear.
(1) Wash out with low-velocity water.
(2) Assure fan runs whenever A/C head pressure
exceeds 1724 kPa (250 psi).
(2) Repair as necessary.
(3) Check for missing air seals-recirculating air path.
(4) Assure correct cooling system parts.
Battery Dead - Suspect Fan Current Draw as Cause
(1) With a good, fully charged battery. (1) a - Assure fan control is operating properly.
(1) b - See charging system in Electrical, Group 8B.
Hot Smell - Suspect Cooling System
(1) Was temperature gauge high? (1) a - Yes, See Gauge Reads High
(1) b - No. See 2, 3, 4, and 5.
(2) Heat shields all in place? (2) a - Yes, See 3, 4, and 5.
(2) b - Repair or replace heat shields.
(3) Fan control operating properly? (3) a - Yes, See 4 and 5.
(3) b - No, See Radiator Fan Control this section.
(4) Heat exchanger air side plugged? (4) Clean as required.
(5) Engine missing or running rich? (5) Repair as required.
Poor Driveability - Suspect Failed Open Thermostat.
(1) Check diagnostics - is code 17 set? (Engine too
cold for too long)
(1) If yes, change thermostat.
Poor Heater Performance - Suspect Failed Open Thermostat
(1) Does gauge read low? (1) See 3
(2) Check coolant level. (2) See 3
(3) Check diagnostics - is code 17 set? (Engine too
cold for too long)
(3) If yes, change thermostat. If no, check heater
bypass valve, which should be closed except in Max
A/C or off mode; if not, see Heater and Air Conditioning
Group, 24.
Steaming, Observe Water Vapor Through Grill or Head Gap at Standstill at Idle - In Wet Weather
(1) This is normal. It is moisture, snow, or water on the
outside of the radiator that evaporates when the
thermostat opens to put hot coolant into the radiator.
This usually occurs in cold weather with no fan or air
flow to blow it away.
(1) Normal condition - no service required.
RADIATOR COOLANT FLOW TEST
To determi ne whether cool ant i s fl owi ng through
the cool i ng system, use the fol l owi ng procedure:
(1) I f engi ne i s col d, i dl e engi ne unti l normal oper-
ati ng temperature i s reached. Then feel the upper
radi ator hose. I f i t i s hot, cool ant i s ci rcul ati ng.
WARNING: DO NOT REMOVE RADIATOR PRES-
SURE CAP WITH THE SYSTEM HOT AND UNDER
PRESSURE BECAUSE SERIOUS BURNS FROM
COOLANT CAN OCCUR.
(2) Remove radi ator pressure cap when engi ne i s
col d, i dl e engi ne unti l thermostat opens, you shoul d
observe cool ant fl ow whi l e l ooki ng down the fi l l er
neck. Once fl ow i s detected i nstal l radi ator pressure
cap.
RADIATOR FAN CONTROL
Fan control i s accompl i shed two ways. A pressure
transducer on the compressor di scharge l i ne sends a
si gnal to the Powertrai n Control Modul e (PCM)
whi ch wi l l acti vate the fan. I n addi ti on to thi s con-
trol , the fan i s turned on by the temperature of the
cool ant whi ch i s sensed by the cool ant temperature
sensor whi ch sends the message to the PCM. The fan
wi l l not run duri ng cranki ng unti l the engi ne starts
no matter what the cool ant temperature i s.
CAUTION: The solid state fan relay is attached to
the left frame rail near the lower radiator support.
The relay bracket, and fastener are used to dissi-
pate heat from the relay. Ensure the relay is prop-
erly attached to prevent the following:
I ntermi ttent engi ne overheati ng.
Rel ay thermal shutdown, or rel ay damage.
ELECTRIC FAN MOTOR TEST
Refer to Powertrai n Di agnosti c Manual for proce-
dure.
TESTING COOLING SYSTEM FOR LEAKS
Wi th engi ne not runni ng, wi pe the radi ator fi l l er
neck seal i ng seat cl ean. The radi ator shoul d be ful l .
Attach the Radi ator Pressure Tool to the radi ator,
as shown i n (Fi g. 12) and appl y 104 kPa (15 psi )
pressure. I f the pressure drops more than 2 psi i n 2
mi nutes, i nspect al l poi nts for external l eaks.
Al l radi ator and heater hoses shoul d be shaken
whi l e at 104 kPa (15 psi ), si nce some l eaks occur onl y
whi l e dri vi ng due to engi ne movement.
I f there are no external l eaks, after the gauge di al
shows a drop i n pressure, detach the tester. Start
engi ne and run the engi ne up to normal operati ng
temperature to open the thermostat and al l ow the
cool ant to expand. Reattach the tester. I f the needl e
on the di al fl uctuates i t i ndi cates a combusti on l eak,
usual l y a head gasket l eak.
RADIATOR FAN OPERATION
Radiator Fan Control A/C Pressure
Fan
Operation
Low
Fan
Speed
30%
High
Fan
Speed
100%
Low
Fan
Speed
30%
High
Fan
Speed
100%
On: 104C
(220F)
110C
(230F)
Fan
Speed
Duty-
Cycles
(Ramps-
up) from
31% to
99%
1,724
Kpa
(250
psi)
2,068
Kpa
(300
psi)Fan
Speed
Duty-
Cycles
(Ramps-
up) from
31% to
99%
Off: 101C
(214F)
Fan
Speed
Duty-
Cycles
(Ramps-
down)
from
99% to
31%
1,710
Kpa
(248
psi)
Fan
Speed
Duty-
Cycles
(Ramps-
down)
from
99% to
31%
Fig. 12 Pressure Testing Cooling System
WARNING: WITH TOOL IN PLACE, PRESSURE
WILL BUILD UP FAST. EXCESSIVE PRESSURE
BUILT UP, BY CONTINUOUS ENGINE OPERATION,
MUST BE RELEASED TO A SAFE PRESSURE
POINT. NEVER PERMIT PRESSURE TO EXCEED 138
kPa (20 psi).
I f the needl e on the di al does not fl uctuate, race
the engi ne a few ti mes. I f an abnormal amount of
cool ant or steam emi ts from the tai l pi pe, i t may
i ndi cate a cool ant l eak caused by a faul ty head gas-
ket, cracked engi ne bl ock, or cracked cyl i nder head.
There may be i nternal l eaks that can be deter-
mi ned by removi ng the oi l di psti ck. I f water gl obul es
appear i ntermi xed wi th the oi l i t wi l l i ndi cate an
i nternal l eak i n the engi ne. I f there i s an i nternal
l eak, the engi ne must be di sassembl ed for repai r.
RADIATOR CAP TO FILLER NECK SEAL PRESSURE
RELIEF CHECK
The pressure cap upper gasket (seal ) pressure
rel i ef can be checked by removi ng the overfl ow hose
at the radi ator fi l l er neck ni ppl e (Fi g. 13). Attach the
Radi ator Pressure Tool to the fi l l er neck ni ppl e and
pump ai r i nto the radi ator. Pressure cap upper gas-
ket shoul d rel i eve at 69-124 kPa (10-18 psi ) and hol d
pressure at 55 kPa (8 psi ) mi ni mum.
WARNING: THE WARNING WORDS DO NOT
OPEN HOT ON THE RADIATOR PRESSURE CAP IS
A SAFETY PRECAUTION. WHEN HOT, PRESSURE
BUILDS UP IN COOLING SYSTEM. TO PREVENT
SCALDING OR INJURY, THE RADIATOR CAP
SHOULD NOT BE REMOVED WHILE THE SYSTEM
IS HOT OR UNDER PRESSURE.
There i s no need to remove the radi ator cap at any
ti me except for the fol l owi ng purposes:
(1) Check and adjust cool ant freeze poi nt. By add-
i ng or subtracti ng cool ant through CRS bottl e.
(2) Refi l l system wi th new cool ant.
(3) Conducti ng servi ce procedures.
(4) Checki ng for vacuum l eaks.
WARNING: IF VEHICLE HAS BEEN RUN
RECENTLY, WAIT 15 MINUTES BEFORE REMOVING
CAP. THEN PLACE A SHOP TOWEL OVER THE CAP
AND WITHOUT PUSHING DOWN ROTATE COUN-
TERCLOCKWISE TO THE FIRST STOP. ALLOW FLU-
IDS TO ESCAPE THROUGH THE OVERFLOW TUBE
AND WHEN THE SYSTEM STOPS PUSHING COOL-
ANT AND STEAM INTO THE CRS TANK AND PRES-
SURE DROPS PUSH DOWN AND REMOVE THE CAP
COMPLETELY. SQUEEZING THE RADIATOR INLET
HOSE WITH A SHOP TOWEL (TO CHECK PRES-
SURE) BEFORE AND AFTER TURNING TO THE
FIRST STOP IS RECOMMENDED.
PRESSURE TESTING RADIATOR CAP
Di p the pressure cap i n water, cl ean any deposi ts
off the vent val ve or i ts seat and appl y cap to end of
Radi ator Pressure Tool . Worki ng the pl unger, bri ng
the pressure to 104 kPa (15 psi ) on the gauge. I f the
pressure cap fai l s to hol d pressure of at l east 97 kPa
(14 psi ) repl ace cap. See CAUTION.
I f the pressure cap tests properl y whi l e posi ti oned
on Radi ator Pressure Tool (Fi g. 14), but wi l l not hol d
pressure or vacuum when posi ti oned on the radi ator.
I nspect the radi ator fi l l er neck and cap top gasket for
i rregul ari ti es that may prevent the cap from seal i ng
properl y.
CAUTION: Radiator Pressure Tool is very sensitive
to small air leaks that will not cause cooling system
problems. A pressure cap that does not have a his-
tory of coolant loss should not be replaced just
because it leaks slowly when tested with this tool.
Add water to the tool. Turn tool upside down and
recheck pressure cap to confirm that cap is bad.
LOW COOLANT LEVEL AERATION
Low cool ant l evel i n a cross fl ow radi ator wi l l
equal i ze i n both tanks wi th engi ne off. Wi th engi ne
Fig. 13 Radiator Pressure Cap Filler Neck
Fig. 14 Pressure Testing Radiator Cap
at runni ng operati ng temperature the hi gh pressure
i nl et tank runs ful l and the l ow pressure outl et tank
drops:
Transmi ssi on oi l wi l l become hotter.
Hi gh readi ng shown on the temperature gauge.
Ai r i n the cool ant can cause l oss of fl ow through
the heater.
Exhaust gas l eaks i nto the cool ant al so can
cause the same probl ems.
DEAERATION
Ai r can onl y be removed from the system by gath-
eri ng under the pressure cap. On the next heat up i t
wi l l be pushed past the pressure cap i nto the CRS
tank by thermal expansi on of the cool ant. I t then
escapes to the atmosphere i n the CRS tank and i s
repl aced wi th sol i d cool ant on cool down.
TEMPERATURE GAUGE INDICATION
At i dl e wi th Ai r Condi ti oni ng off the temperature
gauge wi l l ri se sl owl y to about 5/8 gauge travel , the
fan wi l l come on and the gauge wi l l qui ckl y drop to
about 1/2 gauge travel . Thi s i s normal .
SERVICE PROCEDURES
COOLANT LEVEL CHECK ROUTINE
Do not remove radiator cap for routine cool-
ant level inspections.
The cool ant reserve system provi des a qui ck vi sual
method for determi ni ng the cool ant l evel wi thout
removi ng the radi ator cap. With the engine cold
and not running, si mpl y observe the l evel of the
cool ant i n the reserve tank (Fi g. 3). The cool ant l evel
shoul d be between the mi ni mum and maxi mum
marks.
COOLANT ADDING ADDITIONAL
The radiator cap should not be removed.
When addi ti onal cool ant i s needed to mai ntai n thi s
l evel , i t shoul d be added to the cool ant reserve tank.
Use onl y 50/50 mi x of ethyl ene gl ycol type anti freeze
and water.
COOLANT LEVEL SERVICE
The cool i ng system i s cl osed and desi gned to mai n-
tai n cool ant l evel to the top of the radi ator.
When servi ci ng requi res a cool ant l evel check i n
the radi ator, the engi ne must be off and not under
pressure. Drai n several ounces of cool ant from the
radi ator drai ncock whi l e observi ng the Cool ant
Recovery System (CRS) Tank. Cool ant l evel i n the
CRS tank shoul d drop sl i ghtl y. Then remove the radi -
ator cap. The radi ator shoul d be ful l to the top. I f
not, and the cool ant l evel i n the CRS tank i s at the
MI N mark there i s an ai r l eak i n the CRS system.
Check hose or hose connecti ons to the CRS tank,
radi ator fi l l er neck or the pressure cap seal to the
radi ator fi l l er neck for l eaks.
COOLING SYSTEM DRAINING
Without removing radiator pressure cap and
with system not under pressure, shut engi ne off
and open drai ncock. The cool ant reserve tank shoul d
empty fi rst, then remove radi ator pressure cap. (i f
not, see Testi ng Cool i ng System for l eaks). To vent
2.4L engi ne remove the cool ant temperature sensor
l ocated above water outl et housi ng (Fi g. 15). The 3.0/
3.3/3.8L engi nes have an ai r bl eed vent on the ther-
mostat.
Removal of a sensor i s requi red because the ther-
mostat does not have an ai r vent. Sensor removal
al l ows an ai r bl eed for cool ant to drai n from the
engi ne bl ock.
COOLING SYSTEM REFILLING
Fi rst cl ean system to remove ol d cool ant, see Cool -
i ng System Cl eani ng.
Fi l l the system, usi ng the correct anti freeze as
descri bed i n the Cool ant Secti on. Fi l l the system to
50 percent of i ts capaci ty wi th 100 percent gl ycol .
Then compl ete fi l l i ng system wi th water. The 2.4L
engi ne requi res venti ng by removal of the cool ant
sensor on top of the water outl et connector (Fi g. 15).
When cool ant reaches thi s hol e:
I nstal l cool ant sensor and ti ghten to 7 Nm (60
i n. l bs.) for 2.4L Engi nes.
Fig. 15 Coolant Temperature Sensor2.4L Engine
Drain/Fill
Conti nue fi l l i ng system unti l ful l , thi s provi des bet-
ter heater performance. Be careful not to spill
coolant on drive belts or the generator.
Fi l l cool ant reserve system to at l east the MAX
mark wi th 50/50 sol uti on. I t may be necessary to add
cool ant to the reserve tank after three or four warm
up/cool down cycl es to mai ntai n cool ant l evel between
the MAX and MI N mark. Thi s wi l l al l ow trapped ai r
to be removed from the system.
REMOVAL
(1) Di sconnect negati ve cabl e from battery.
(2) Rai se vehi cl e on a hoi st. Remove ri ght i nner
spl ash shi el d.
(3) Remove accessory dri ve bel ts. Refer to Acces-
sory Dri ve Bel t servi ce i n thi s secti on.
(4) Drai n cool i ng system. Refer to Cool i ng System
Drai ni ng i n thi s secti on.
(5) Support engi ne from the bottom and remove
ri ght engi ne mount.
(6) Remove ri ght engi ne mount bracket.
(7) Remove ti mi ng bel t. Refer to Group 9, Engi ne
for procedure.
(8) Remove ti mi ng bel t i dl er pul l ey.
(9) Hol d camshaft sprocket wi th Speci al tool
C-4687 and adaptor C-4687-1 whi l e removi ng bol t.
Remove both cam sprockets.
(10) Remove rear ti mi ng bel t cover.
(11) Remove water pump attachi ng screws to
engi ne (Fi g. 16).
INSTALLATION
(1) I nstal l new O-ri ng gasket i n water pump body
O-ri ng groove (Fi g. 17).
CAUTION: Make sure O-ring is properly seated in
water pump groove before tightening screws. An
improperly located O-ring may cause damage to the
O-ring and cause a coolant leak.
(2) Assembl e pump body to bl ock and ti ghten
screws to 12 Nm (105 i n. l bs.) (Fi g. 16). Pressuri ze
cool i ng system to 15 psi wi th pressure tester and
check water pump shaft seal and O-ri ng for l eaks.
(3) Rotate pump by hand to check for freedom of
movement.
(4) I nstal l rear ti mi ng bel t cover.
(5) I nstal l camshaft sprockets and torque bol ts to
101 Nm (75 ft. l bs.).
(6) I nstal l ti mi ng bel t i dl er pul l ey and torque
mounti ng bol t to 61 Nm (45 ft. l bs.).
(7) I nstal l ti mi ng bel t. Refer to Group 9, Engi ne,
2.4L Ti mi ng Bel t.
(8) I nstal l ri ght engi ne mount bracket and engi ne
mount. Refer to Group 9 for procedure.
(9) Fi l l cool i ng system. See Cooling System Fill-
ing.
(10) I nstal l accessory dri ve bel ts, Refer to Acces-
sory Dri ve Bel ts, i n thi s secti on.
(11) Lower vehi cl e and connect battery cabl e.
WATER PUMP INLET TUBE 2. 4L ENGINE
REMOVAL
(1) Drai n cool i ng system. Refer to procedure out-
l i ned i n thi s secti on.
(2) Remove upper radi ator hose to access the hose
connecti ons at the i nl et tube.
(3) Remove l ower radi ator hose and heater hose
from the i nl et tube (Fi g. 18).
(4) Remove the 2 fasteners that hol d the i nl et
tube to the bl ock.
(5) Rotate tube whi l e removi ng the tube from the
engi ne bl ock (Fi g. 19).
INSTALLATION
(1) I nspect the O-ri ng for damage before i nstal l i ng
the tube i nto the cyl i nder bl ock (Fi g. 19).
(2) Lube O-ri ng wi th cool ant and i nstal l i nto the
cyl i nder bl ock openi ng.
(3) I nstal l 2 fasteners and ti ghten to 12 Nm (105
i n. l bs.).
(4) Connect l ower radi ator hose and heater hose
to i nl et tube (Fi g. 18).
Fig. 17 Water Pump Body
(5) I nstal l upper radi ator hose.
(6) Fi l l cool i ng system. Refer to procedure outl i ned
i n thi s secti on.
REMOVAL
(1) Drai n cool i ng system. Refer to Drai ni ng Cool -
i ng System i n thi s group.
(2) To gai n access to water pump refer to Group 9,
Engi ne for Ti mi ng Bel t Removal .
(3) Remove mounti ng bol ts.
(4) Separate pump from water i nl et pi pe (Fi g. 20)
and (Fi g. 21) and remove.
INSPECTION
Repl ace the water pump i f i t has any of the fol l ow-
i ng defects.
(1) Damage or cracks on the pump body.
(2) Cool ant l eaks, i f the shaft seal i s l eaki ng, evi -
dent by traces of cool ant l eaks from vent hol e A i n
(Fi g. 21).
(3) I mpel l er rubs the i nsi de of pump.
(4) Loose or rough turni ng beari ng.
Fig. 18 Water Pump Inlet Tube Hose Connections
Fig. 19 Water Pump Inlet Tube Service
Fig. 21 Water Pump Inspection
Fig. 22 Water Pipe O-Ring
INSTALLATION
(1) Cl ean al l gasket and O-ri ng surfaces on pump
and water pi pe i nl et tube.
(2) I nstal l new O-ri ng on water i nl et pi pe (Fi g.
22). Wet the O-ri ng (wi th water) to ease assembl y.
CAUTION: Keep the O-ring free of oil or grease.
(3) I nstal l new gasket on water pump and i nstal l
pump i nl et openi ng over water pi pe, press assembl y
to cause water pi pe i nserti on i nto pump housi ng.
(4) I nstal l pump to bl ock mounti ng bol ts and
ti ghten to 27 Nm (20 ft. l bs.).
(5) See Ti mi ng Bel t i n Engi ne, Group 9 and
i nstal l ti mi ng bel t. Reassembl e engi ne.
(6) Fi l l cool i ng system. See Refi l l i ng Cool i ng Sys-
tem.
WATER PUMP 3. 3/3. 8L ENGINES
REMOVAL
(1) Drai n Cool i ng System. Refer to Drai ni ng Cool -
i ng System i n thi s group.
(2) Remove Pol y-V Dri ve Bel t.
(3) Remove ri ght front l ower fender shi el d.
(4) Remove pump pul l ey bol ts and remove pul l ey.
(5) Remove pump mounti ng screws (Fi g. 23).
Remove water pump.
(6) Remove and di scard O-ri ng seal .
(7) Cl ean O-ri ng groove and O-ri ng surfaces on
pump and chai n case cover. Take care not to scratch
or gouge seal i ng surface.
INSTALLATION
(1) I nstal l new O-ri ng i nto groove (Fi g. 24).
(2) I nstal l pump to chai n case cover. Torque
screws to 12 Nm (105 i n. l bs.)
movement.
(4) Posi ti on pul l ey on pump. I nstal l screws and
torque to 30 Nm (250 i n. l bs.).
(5) I nstal l dri ve bel t. See Accessory Dri ve Bel ts i n
thi s group.
(6) I nstal l ri ght front l ower fender shi el d.
(7) Refi l l Cool i ng System. See Refi l l i ng Cool i ng
System.
THERMOSTAT 2. 4L ENGINE
REMOVAL
(1) Drai n cool i ng system down bel ow the thermo-
stat l evel . Refer to Drai ni ng Cool i ng System i n thi s
group.
(2) Remove thermostat housi ng bol ts and housi ng
(Fi g. 25).
(3) Remove thermostat, di scard gasket and cl ean
both gasket seal i ng surfaces.
Fig. 23 Water Pump 3.3/3.8L Engines
Fig. 24 Water Pump Body
Fig. 25 Thermostat, Housing, and Outlet
Connector2.4L Engine
INSTALLATION2.4L ENGINE
(1) Pl ace a new gasket (di pped i n cl ean water) on
the engi ne outl et connector surface. Center the ther-
mostat i n thermostat housi ng (Fi g. 25).
(2) Pl ace the engi ne outl et connector and gasket
over the thermostat, maki ng sure thermostat i s
seated i n the thermostat housi ng.
(3) Bol t outl et connector to thermostat housi ng
(Fi g. 25). Ti ghten bol ts to 28 Nm (250 i n. l bs.).
(4) Refi l l the cool i ng system to the proper l evel .
Refer to Cool i ng System Refi l l i ng outl i ned i n thi s sec-
ti on for procedure
THERMOSTAT 3. 0L ENGINE
REMOVAL
group.
(Fi g. 26).
INSTALLATION3.0L ENGINE
(1) Center thermostat i n water box pocket. Check
that the fl ange i s seated correctl y i n the countersunk
porti on of the i ntake mani fol d water box (Fi g. 26)
and (Fi g. 27).
(2) I nstal l new gasket on water box.
(3) I nstal l housi ng over gasket and thermostat
and ti ghten bol ts to 12 Nm (105 i n. l bs.).
ti on for procedure.
THERMOSTAT 3. 3/3. 8L ENGINES
REMOVAL
stat l evel . Refer to Cool i ng System Drai ni ng i n thi s
secti on.
(Fi g. 28).
Fig. 26 Thermostat, Housing, and Water Box3.0L
Engine
Fig. 27 Thermostat Installed3.0L Engine
Fig. 28 Thermostat, Housing, and Water Box3.3/
3.8L Engines
INSTALLATION
(1) Pl ace a new gasket (di pped i n water) on the
thermostat housi ng surface, center thermostat i nto
openi ng i n the i ntake mani fol d water box.
(2) Pl ace housi ng and gasket over the thermostat,
maki ng sure thermostat i s i n the recess provi ded
(Fi g. 28).
(3) Bol t housi ng to i ntake mani fol d, ti ghten bol ts
to 28 Nm (250 i n. l bs.).
ti on for procedure.
RADIATOR
REMOVAL
WARNING: DO NOT REMOVE THE CYLINDER
BLOCK PLUG OR THE RADIATOR DRAINCOCK
WITH THE SYSTEM HOT AND UNDER PRESSURE
BECAUSE SERIOUS BURNS FROM COOLANT CAN
OCCUR.
i ng System of thi s secti on.
(3) Remove ai r i ntake resonator.
(4) Remove cool ant reserve system tank to fi l l er
neck tube hose.
(5) Di sconnect fans from the connector l ocated on
the l eft si de of the fan modul e.
(6) Remove the Cool ant Recovery System (CRS)
tank retai ni ng screw from the upper radi ator cl osure
panel crossmember.
(7) Di sconnect the upper radi ator mounti ng
screws from the crossmember. Di sconnect the engi ne
bl ock heater wi re i f equi pped.
(8) Remove the upper radi ator cl osure panel
crossmember. Refer to Group 23 Body for procedure.
(9) Remove ai r cl eaner assembl y.
(10) Di sconnect automati c transmi ssi on oi l cool er
l i nes at radi ator and pl ug.
(11) Di sconnect i nl et and outl et hoses from the
radi ator. Remove the l ower hose cl i p from the fan
modul e.
(12) Remove A/C condenser fasteners and sepa-
rate the condenser from the radi ator (Fi g. 29). Veri fy
the condenser i s supported i n posi ti on.
(13) Remove A/C fi l ter/dryer mounti ng bracket, 2
bol ts to the fan modul e, and 2 nuts to the fi l ter/dryer.
(14) Radi ator can now be l i fted free from engi ne
compartment. Care should be taken not to dam-
age radiator cooling fins or water tubes during
removal.
INSTALLATION
(1) Be sure the air seals are in position before
radiator is installed. Sl i de radi ator down i nto posi -
ti on behi nd cl osure panel . Seat the radi ator wi th the
rubber i sol ators i nto the mounti ng hol es provi ded,
wi th a 10 l bs. force.
(2) I nstal l A/C fi l ter/dryer and mounti ng bracket
onto fan modul e.
(3) I nstal l Ai r Condi ti oni ng Condenser onto the
radi ator (Fi g. 29).
(4) Unpl ug and connect automati c transmi ssi on
oi l cool er l i nes to radi ator.
(5) I nstal l i nl et and outl et radi ator hoses (i ncl ud-
i ng cool ant reserve hose) and connect the fan motor
el ectri cal connecti on.
(6) I nstal l ai r cl eaner assembl y.
(7) I nstal l the upper radi ator cl osure panel cross-
member. Refer to Group 23 Body for procedure.
(8) I nstal l the upper radi ator mounti ng screws.
Ti ghten radi ator mounti ng bol ts to 12 Nm (105 i n.
l bs.). Connect the engi ne bl ock heater wi re i f
equi pped.
(9) I nstal l the Cool ant Recovery System (CRS)
tank retai ni ng screw to the upper radi ator cl osure
panel crossmember.
(10) I nstal l ai r i ntake resonator.
(11) Fi l l cool i ng system. Refer to Cool i ng System
Fi l l i ng i n thi s secti on.
(12) Connect negati ve cabl e to battery.
RADIATOR DRAINCOCK
REMOVAL
CAUTION: Use of pliers on draincock is not rec-
ommended. Damage may occur to part. Draincock
should not be removed unless leakage observed.
(1) Turn the drai ncock stem countercl ockwi se to
unscrew the stem. When the stem i s unscrewed to
Fig. 29 Air Conditioning Condenser Mounting
Fasteners
the end of the threads turn back 1/8 turn and, pul l
the stem (Fi g. 30) from the radi ator tank.
INSTALLATION
(1) Push the drai ncock assembl y body i nto the
tank openi ng unti l i t snaps i nto pl ace.
(2) Ti ghten the drai ncock stem by turni ng cl ock-
wi se unti l i t stops.
FAN MODULE
REMOVAL
There are no repai rs to be made to the fan or
shroud assembl y. I f the fan i s warped, cracked, or
otherwi se damaged, i t must be repl aced as a assem-
bl y (Fi g. 31).
(1) Rai se the vehi cl e on hoi st.
(2) Remove the radi ator outl et hose from hose
retai ni ng cl i p and remove cl i p from shroud.
(3) Remove l ower auxi l i ary transmi ssi on cool er
l i nes from retai ni ng cl i ps on the fan modul e shroud,
i f equi pped.
(4) Lower the vehi cl e. Remove the ai r i ntake res-
onator from the throttl e body and ai r cl eaner assem-
bl y.
(5) Di sconnect the fans el ectri cal connector
l ocated on the l eft si de of the fan modul e.
(6) Remove the Cool ant Recovery System (CRS)
attachi ng screw from the upper crossmember.
(7) Remove upper gri l l to crossmember val ence
panel .
(8) Di sconnect the upper radi ator mounts from the
crossmember. Remove the upper crossmember. Refer
to Group 23 Body for procedure.
(9) Remove the ai r cl eaner assembl y.
(10) Remove fan modul e retai ni ng fasteners (Fi g.
31).
(11) Remove upper auxi l i ary transmi ssi on cool er
l i nes from retai ni ng cl i ps on the fan modul e shroud,
i f equi pped.
(12) Di sconnect and pl ug the transmi ssi on l i ne
from the radi ator fi tti ng on the l ower l eft si de.
(13) Rai se vehi cl e on the hoi st and remove the fi l -
ter/dri er, fan modul e and radi ator mounti ng bol ts
l ocated on the l ower ri ght of the modul e.
(14) Lower the vehi cl e on hoi st and remove the
upper fan modul e to radi ator retai ni ng cl i ps.
(15) Remove the fan modul e from the vehi cl e.
INSTALLATION
(1) I nstal l fan modul e assembl y i nto attachi ng
cl i ps on the radi ator.
(2) I nstal l the upper fan modul e to radi ator
retai ni ng cl i ps.
(3) Rai se vehi cl e on the hoi st and i nstal l the fi l -
ter/dri er, fan modul e and radi ator mounti ng fasten-
ers l ocated on the l ower ri ght of the modul e.
(4) Lower the vehi cl e. Connect the transmi ssi on
l i ne to the radi ator fi tti ng on the l ower l eft si de.
(5) I nstal l the upper auxi l i ary transmi ssi on cool er
l i nes to the retai ni ng cl i ps on the fan modul e shroud,
i f equi pped.
(6) I nstal l fan modul e retai ni ng fasteners (Fi g.
31). Ti ghten to 12 Nm (105 i n. l bs.).
(7) I nstal l the ai r cl eaner assembl y.
(8) I nstal l the crossmember. Refer to Group 23
Body for procedure. Connect the upper radi ator
mounts to the crossmember. Ti ghten fasteners to 12
Nm (105 i n. l bs.).
(9) I nstal l the Cool ant Recovery System (CRS)
attachi ng screw to the upper crossmember. Ti ghten
to 2 Nm (18 i n. l bs.).
(10) I nstal l upper gri l l to crossmember val ence
panel .
(11) Connect the fans to the connector l ocated on
the l eft si de of the fan modul e.
(12) I nstal l the ai r i ntake resonator to the throttl e
body and ai r cl eaner assembl y.
Fig. 30 Draincock Disassembled
Fig. 31 Fan Module
(13) Rai se the vehi cl e. I nstal l the l ower auxi l i ary
transmi ssi on cool er l i nes to the retai ni ng cl i ps on the
fan modul e shroud, i f equi pped.
(14) I nstal l outl et hose retai ner cl i p to the shroud.
I nstal l the radi ator outl et hose to the retai ni ng cl i p.
ENGINE BLOCK HEATER
REMOVAL
(1) Drai n cool ant from radi ator and cyl i nder bl ock.
Refer to Cool i ng System Drai n, Cl ean, Fl ush and
Refi l l of thi s secti on for procedure.
(2) Remove power cord pl ug from heater.
(3) Loosen screw i n center of heater. Remove
heater assembl y.
INSTALLATION
(1) Thoroughl y cl ean core hol e and heater seat.
(2) I nsert heater assembl y wi th el ement l oop posi -
ti oned upward.
(3) Wi th heater seated, ti ghten center screw
securel y to assure a posi ti ve seal .
(4) Fi l l cool i ng system wi th cool ant to the proper
l evel , vent ai r, and i nspect for l eaks. Pressuri ze sys-
tem wi th Radi ator Pressure Tool before l ooki ng for
l eaks.
(5) I nstal l power cord pl ug to heater.
ACCESSORY DRIVE BELTS 2. 4L
REMOVAL/INSTALLATION-ADJ UST
GENERATOR AND AIR CONDITIONING
(1) Loosen l ower generator pi vot bol t and upper
l ocki ng nut, then l oosen adjusti ng bol t (Fi g. 32) to
remove bel t tensi on.
CAUTION: Belt damage may occur if the following
procedure is not performed.
(2) Ti ghten l ock nut to 21 Nm (180 i n. l bs.) and
torque generator pi vot bol t to 54 Nm (40 ft. l bs.). To
assure proper al i gnment of generator assembl y.
Adjust bel t tensi on by ti ghteni ng the adjusti ng bol t
unti l proper bel t tensi on i s obtai ned. Refer to tensi on
speci fi cati on i n Bel t Tensi on Chart.
(3) Torque l ock nut to 54 Nm (40 ft. l bs.).
POWER STEERING PUMP
(1) From on top of the vehi cl e l oosen l ocki ng nuts
D and F (Fi g. 33).
(2) From under the vehi cl e l oosen the pi vot bol t E.
Loosen adjusti ng bol t G unti l bel t can be removed.
(3) After i nstal l i ng a new bel t, adjust bel t tensi on
by ti ghteni ng the adjusti ng bol t unti l the proper ten-
si on obtai ned. Refer to tensi on speci fi cati on i n Bel t
Tensi on Chart.
(4) Ti ghten l ocki ng nuts D and F to 54 Nm (40 ft.
l bs.).
(5) Ti ghten pi vot bol t E to 54 Nm (40 ft. l bs.)
Fig. 32 Air Conditioning Compressor/Generator
Belts2.4L
Fig. 33 Power Steering Pump Adjustment
ACCESSORY DRIVE BELTS 3. 0L
GENERATOR/POWER STEERING PUMP BELT
REMOVAL/INSTALLATION
The Pol y-V generator/power steeri ng pump bel t i s
provi ded wi th a dynami c tensi oner (Fi g. 34) to mai n-
tai n proper bel t tensi on. To remove or i nstal l thi s
bel t, appl y force i n a cl ockwi se di recti on to the ten-
si oner pul l ey bol t (Fi g. 34).
AIR CONDITIONING BELT
REMOVAL
To remove the ai r condi ti oni ng compressor dri ve
bel t, fi rst l oosen the i dl er pul l ey l ock nut, then turn
the adjusti ng screw to l ower the i dl er pul l ey (Fi g.
35).
INSTALLATION/ADJUSTMENT
To adjust the air conditioning drive belt,
l oosen the i dl er pul l ey l ock nut (Fi g. 35) and adjust
bel t tensi on by ti ghteni ng adjusti ng screw. Refer to
Proper Bel t Tensi on and Bel t Tensi on Chart i n thi s
Secti on for procedure. Ti ghten pul l ey l ock nut to 54
Nm (40 ft. l bs.) after adjustment.
ACCESSORY DRIVE BELT 3. 3/3. 8L
REMOVE/INSTALL
GENERATOR, POWER STEERING PUMP, AIR CONDITIONING
COMPRESSOR AND WATER PUMP DRIVE BELT
The Pol y-V Dri ve bel t i s provi ded wi th a dynami c
tensi oner (Fi g. 36) to mai ntai n proper bel t tensi on.
To remove or i nstal l thi s bel t.
(1) Rai se vehi cl e on hoi st.
(2) Remove ri ght front spl ash shi el d.
(3) Rel ease tensi on by rotati ng the tensi oner
cl ockwi se (Fi g. 36).
(4) Reverse above procedure to i nstal l .
WATER PUMP
i ng defects.
(2) Cool ant l eaks; i f the seal i s l eaki ng, thi s wi l l be
evi dent by traces of thi ck deposi ts of greeni sh-brown
dri ed gl ycol runni ng down the pump body and com-
ponents bel ow. A thi n bl ack stai n bel ow pump weep
hol e i s consi dered normal operati on.
(3) I mpel l er rubs i nsi de of chai n case cover
3.3/3.8L or cyl i nder bl ock 2.4L engi nes.
(4) Excessi vel y l oose or rough turni ng beari ng.
Fig. 34 Release Belt Tensioner3.0L
Fig. 35 Air Conditioning Drive Belt3.0L Engine
Fig. 36 Accessory Drive Belt3.3/3.8L Engines
NOTE: It is normal for the water pump to weep a
small amount of coolant from the weep hole (black
stain on water pump body). Do not replace the
water pump if this condition exists. Replace the
water pump if a heavy deposit or a steady flow of
green/brown engine coolant is evident on water
pump body from the weep hole (shaft seal failure).
Be sure to perform a thorough analysis before
replacing water pump.
ACCESSORY DRIVE BELT
When i nspecti ng serpenti ne dri ve bel ts, smal l
cracks that run across the ri bbed surface of the bel t
from ri b to ri b (Fi g. 37), are consi dered normal . these
are not reasons to repl ace the bel t. However, cracks
runni ng al ong the ri b (not across) are not normal .
Any bel t wi th cracks runni ng al ong the ri b must be
repl aced (Fi g. 37). Al so repl ace the bel t i f i t has
excessi ve wear, frayed cords or severe gl azi ng.
RADIATOR PRESSURE CAP
INSPECTION
Hol d the cap i n hand, right side up. The vent
val ve at the bottom of the cap shoul d open. I f the
rubber gasket has swol l en and prevents the val ve
from openi ng, repl ace the cap.
Hol d the cl eaned cap i n hand upside down. I f any
l i ght shows between vent val ve and rubber gasket,
repl ace cap. Do not use a replacement cap that
has a spring to hold the vent shut.
Repl acement cap must be of the type desi gned for
cool ant reserve system wi th a compl etel y seal ed di a-
phragm spri ng, and rubber gasket to seal to fi l l er
neck top surface. Thi s desi gn assures cool ant return
to radi ator.
COOLING SYSTEM CLEANING
Drai n cool i ng system (see: Cooling System
Draining ) and refi l l wi th cl ean water (see: Cooling
System Refilling ). Run engi ne wi th radi ator cap
i nstal l ed unti l upper radi ator hose i s hot. Stop
engi ne and drai n water from system. I f water i s
di rty; fi l l , run, and drai n system agai n, unti l water
runs cl ear.
REVERSE FLUSHING THE RADIATOR
Drai n cool i ng system and remove radi ator hoses
from engi ne. I nstal l sui tabl e fl ushi ng gun i n radi ator
l ower hose. Fi l l radi ator wi th cl ean water and turn
on ai r i n short bl asts.
CAUTION: Internal radiator pressure must not
exceed 138 kPa (20 psi) as damage to radiator may
result. Continue this procedure until water runs
clear.
REVERSE FLUSHING THE ENGINE
Drai n radi ator (see: Draining Cooling System )
and remove hoses from radi ator. Remove engi ne ther-
mostat and rei nstal l thermostat housi ng. I nstal l sui t-
abl e fl ushi ng gun to thermostat housi ng hose. Turn
on water, and when engi ne i s fi l l ed, turn on ai r, but
no hi gher than 138 kPa (20 psi ) i n short bl asts. Al l ow
engi ne to fi l l between bl asts of ai r. Conti nue thi s pro-
cedure unti l water runs cl ean. Rei nstal l thermostat
usi ng a new housi ng gasket. Fi l l cool i ng system (See
Refilling).
CHEMICAL CLEANING
One type of corrosi on encountered wi th al umi num
cyl i nder heads i s al umi num hydroxi de deposi ts. Cor-
rosi on products are carri ed to the radi ator and depos-
i ted when cool ed off. They appear as dark grey when
wet and whi te when dry. Thi s corrosi on can be
removed wi th a two part cl eaner (oxal i c aci d and
neutral i zer) avai l abl e i n auto parts outl ets. Fol l ow
manufacturers di recti ons for use.
ADJ USTMENTS
PROPER BELT TENSION
Sati sfactory performance of the bel t dri ven accesso-
ri es depends on proper bel t tensi on. Bel t tensi oni ng
shoul d be performed wi th the ai d of a Burroughs
gauge Speci al Tool C-4162. Because of space l i mi ta-
ti ons i n the engi ne compartment, the use of the
gauge may be restri cted. Rai se the vehi cl e on a hoi st
Fig. 37 Serpentine Drive Belt Wear Patterns
and the remove the spl ash shi el d to gai n access to
the dri ve bel ts.
BELT TENSION GAUGE METHOD
Use bel t tensi oni ng Speci al Tool Ki t C-4162 for:
CAUTION: The Burroughs gauge for the Poly-V
belt is not to be used on the V-belt. These gauges
are not interchangeable.
For conventi onal V-bel ts affi x the Burroughs
gauge (Speci al Tool C-4162) to the bel t. Adjust the
bel t tensi on for New or Used bel t as prescri bed i n the
Bel t Tensi on Chart.
For a Pol y-V bel t affi x the Pol y-V Burroughs
gauge to the bel t and then appl y speci fi ed tensi on to
the bel t as prescri bed i n the Bel t Tensi on Chart
Adjust bel t tensi on for a New or Used bel t as pre-
scri bed i n the Bel t Tensi on Chart.
BELT TENSION CHART
SPECIFICATIONS
COOLING SYSTEM CAPACITY
TORQUE CHART
DESCRIPTION TORQUE
Thermostat Housing
Bol ts2.4L & 3.3/3.8L . . . . . .28 Nm (250 i n. l bs.)
Bol ts3.0L . . . . . . . . . . . . . . .12 Nm (105 i n. l bs.)
Water Pump Mounting
Bol ts2.4L & 3.3/3.8L . . . . . .12 Nm (250 i n. l bs.)
Bol ts3.0L . . . . . . . . . . . . . . .27 Nm (240 i n. l bs.)
Water Pump Inlet Tube
Bol ts2.4L . . . . . . . . . . . . . . .12 Nm (250 i n. l bs.)
Bol ts3.0L . . . . . . . . . . . . . . . .11 Nm (94 i n. l bs.)
Water Pump Pulley
Bol ts3.3/3.8L . . . . . . . . . . . .28 Nm (250 i n. l bs.)
Transaxle Oil Cooler Hose
Cl ampsAl l Engi nes . . . . . . . . .2 Nm (18 i n. l bs.)
Radiator Mounting Upper Bracket
NutAl l Engi nes . . . . . . . . . .12 Nm (105 i n. l bs.)
SPECIAL TOOLS
COOLING
ACCESSORY DRIVE
BELT
GAUGE
2.4L ENGINE
A/C COMPRESSOR /
GENERATOR
NEW 190 LB.
USED 115 LB.
POWER STEERING NEW 140 LB.
USED 90 LB.
3.0L ENGINE
A/C COMPRESSOR NEW 150 LB.
USED 80 LB.
GENERATOR / POWER
STEERING
DYNAMIC TENSIONER
3.3/3.8L ENGINES
A/C COMPRESSOR DYNAMIC TENSIONER
GENERATOR / WATER
PUMP / POWER
STEERING
DYNAMIC TENSIONER
Engine Standard Duty Trailer Tow or
Heavy Duty
Front
Heater
Rear
Heater
Front
Heater
Rear
Heater
2.4L 10.6
liters*
(11.23
qts.)*
N/A N/A N/A
3.0L 12.3
liters*
(13.0
qts.)*
N/A N/A 15.0
liters*
(15.9
qts.)*
3.3/3.8L 12.5
liters*
15.26
liters*
12.5
liters*
15.26
liters*
(13.23
qts.)*
(16.13
qts.)*
(13.23
qts.)*
(16.13
qts)*
*Includes Heater and Coolant Recovery Tank Filled to
Max Level.
Belt Tension Gauge C-4162
COOLING SYSTEM
CONTENTS
page page
GENERAL INFORMATION
COOLANT PRESSURE BOTTLE . . . . . . . . . . . . 1
COOLING SYSTEM 2.0L GASOLINE . . . . . . 1
COOLING SYSTEM 2.5L VM DIESEL . . . . . 1
LOW COOLANT LEVEL SENSOR . . . . . . . . . . . 1
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
AUTOMATIC BELT TENSIONER . . . . . . . . . . . . 6
BELT TENSION . . . . . . . . . . . . . . . . . . . . . . . . . 5
COOLANT PERFORMANCE . . . . . . . . . . . . . . . 5
PRESSURE/VENT CAP . . . . . . . . . . . . . . . . . . . 4
THERMOSTAT OPERATION . . . . . . . . . . . . . . . 4
THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . 6
WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE PROCEDURES
ADDING ADDITIONAL COOLANT . . . . . . . . . . . 7
DRAINING COOLING SYSTEM . . . . . . . . . . . . . 7
REFILLING COOLING SYSTEM . . . . . . . . . . . . 7
ENGINE THERMOSTAT 2.0L GASOLINE . . . 9
GENERATOR/POWER STEERING BELT 2.5L
VM DIESEL . . . . . . . . . . . . . . . . . . . . . . . . . 10
RADIATOR 2.5L VM DIESEL . . . . . . . . . . . 9
THERMOSTAT 2.5L VM DIESEL . . . . . . . . . 9
WATER PUMP BELT 2.5L VM DIESEL . . . 10
WATER PUMP 2.0L GASOLINE . . . . . . . . . 7
WATER PUMP 2.5L VM DIESEL . . . . . . . . 8
WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . 10
ADJUSTMENTS
BELT TENSION CHART . . . . . . . . . . . . . . . . . 11
BELT TENSION GAUGE METHOD . . . . . . . . . 11
SPECIFICATIONS
COOLING SYSTEM CAPACITY . . . . . . . . . . . . 12
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . 12
SPECIAL TOOLS
COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
GENERAL INFORMATION
COOLING SYSTEM 2. 0L GASOLINE
The 2.0L gasol i ne engi ne cool i ng system consi sts of
an engi ne cool i ng modul e, thermostat, cool ant, a
water pump to ci rcul ate the cool ant. The engi ne cool -
i ng modul e may consi st of a radi ator, el ectri c fan
motors, fan, shroud, cool ant reserve system, hoses,
cl amps, ai r condi ti on condenser.
When the Engi ne i s col d: The thermostat i s
cl osed; the cool i ng system has no fl ow through the
radi ator. The cool ant fl ows through the engi ne,
heater system and bypass.
When the Engi ne i s warm: Thermostat i s open;
the cool i ng system has fl ow through radi ator, engi ne,
heater system and bypass.
COOLING SYSTEM 2. 5L VM DIESEL
The cool i ng system has a radi ator, cool ant, el ectri c
fan motors, shroud, pressure cap, thermostat, cool ant
pressure bottl e, hoses, a water pump to ci rcul ate the
cool ant, to compl ete the ci rcui t. Cool ant fl ow for the
VM di esel engi ne i s shown i n (Fi g. 1).
COOLANT PRESSURE BOTTLE
2.5L VM DIESEL
Thi s system works wi th the pressure cap to use
thermal expansi on and contracti on of the cool ant to
keep the cool ant free of trapped ai r. I t provi des some
reserve cool ant to cover mi nor l eaks and evaporati on
or boi l i ng l osses. The cool ant pressure bottl e l ocati on
for 2.5L di esel i s above the cyl i nder head cover (Fi g.
2).
LOW COOLANT LEVEL SENSOR
The l ow cool ant l evel sensor checks for l ow cool ant
l evel i n the cool ant tank. A si gnal wi l l be sent from
thi s sensor to the Body Control Modul e (BCM). When
the BCM determi nes l ow cool ant l evel for 30 conti n-
uous seconds, the i nstrument panel mounted l ow
cool ant l evel warni ng l amp wi l l be i l l umi nated. The
sensor i s l ocated on the front si de of the cool ant tank
(Fi g. 4). For i nformati on, refer to Group 8E, I nstru-
ment Panel and Gauges.
I f thi s l amp i s i l l umi nated, i t i ndi cates the need to
fi l l the cool ant tank and check for l eaks.
NS/GS COOLING SYSTEM 7 - 1
RADIATOR
The radi ators are cross-fl ow types (hori zontal
tubes) wi th desi gn features that provi de greater
strength al ong wi th suffi ci ent heat transfer capabi l i -
Fig. 1 Cooling System Operation 2.5L VM Diesel
Fig. 2 Coolant Pressure Bottle 2.5L VM Diesel
Fig. 3 Low Coolant Warning Sensor Connector
2.5L VM Diesel
7 - 2 COOLING SYSTEM NS/GS
ti es to keep the engi ne sati sfactori l y cool ed (Fi g. 5)
and (Fi g. 6).
CAUTION: Plastic tanks, while stronger then brass
are subject to damage by impact, such as wrenches
etc., or by excessive torque on hose clamps.
I f the pl asti c tank i s damaged, repl ace the radi a-
tor.
WATER PUMP
2.0L GASOLINE
The water has a di ecast al umi num body and hous-
i ng wi th a stamped steel i mpel l er. The water pump
bol ts di rectl y to the bl ock (Fi g. 7). Cyl i nder bl ock to
water pump seal i ng i s provi ded by a rubber O-ri ng.
The water pump i s dri ven by the ti mi ng bel t. Refer
to Group 9, Engi ne secti on for component removal to
access the water pump.
NOTE: The water pump on all models can be
replaced without discharging the air conditioning
system.
2.5L VM DIESEL
The Di esel engi ne water pump has an al umi num
body and housi ng wi th a stamped steel i mpel l er. The
pump uses an O-ri ng gasket between body and hous-
i ng. The water pump i s dri ven by the accessory dri ve
bel t, and the pump housi ng i s bol ted to the cyl i nder
bl ock (Fi g. 9).
NOTE: The water pump on all models can be
replaced without discharging the air conditioning
system.
Fig. 4 Low Coolant Level Sensor
Fig. 5 Cooling Module 2.0LGasoline
Fig. 6 Cooling Module VM Diesel
THERMOSTAT OPERATION
2.5 VM DIESEL
The engi ne cool i ng thermostats are wax pel l et
dri ven, reverse poppet choke type. They are desi gned
to provi de the fastest warm up possi bl e by prevent-
i ng l eakage through them and to guarantee a mi ni -
mum engi ne operati ng temperature (Fi g. 10). The
thermostat has a hol e to bl eed off ai r i n the cool i ng
system duri ng engi ne warm up. The thermostat
begi ns to open at 80 C 2 (176 F 4).
PRESSURE/VENT CAP
WARNING: Engine coolant can reach temperatures
of 200 fahrenheit or greater. If the cooling system
is opened with coolant at a high temperature, hot
coolant can be forced out of the system under high
pressures, causing personal injury. Allow system to
cool down prior to removing the pressure cap.
The pressure/vent cap i s secured to the cool ant
tank neck by a means of a cam l ock system. Thi s cap
rel eases excess pressure at some poi nt wi thi n a
range of 90-117 kPa (13- 17 psi ) for gasol i ne engi nes,
and 110124 kPa (1618 psi ) for di esel engi nes. The
actual pressure rel i ef poi nt (i n pounds) i s l abel ed on
top of the cap (Fi g. 11).
The cool i ng system wi l l operate at pressures
sl i ghtl y above atmospheri c pressure. Thi s resul ts i n a
hi gher cool ant boi l i ng poi nt al l owi ng i ncreased radi -
ator cool i ng capaci ty. The cap (Fi g. 11) contai ns a
spri ng-l oaded pressure rel i ef val ve. Thi s val ve opens
when system pressure reaches approxi matel y 103
kPa (15 psi ).
When the engi ne i s cool i ng down, vacuum i s
formed wi thi n the cool i ng system. To prevent col l apse
of the radi ator and cool ant hoses from thi s vacuum, a
vacuum val ve i s used wi thi n the cap. Thi s val ve pre-
vents excessi ve pressure di fferences from occurri ng
between the cl osed cool i ng system and the atmo-
sphere. I f the vacuum val ve i s stuck shut, the radi a-
tor and/or cool i ng system hoses wi l l col l apse on cool -
down.
Fig. 7 Water Pump2.0L Gasoline Engine
Fig. 8 Water Pump2.0L Gasoline Engine
Fig. 9 Water Pump2.5L VM Diesel
Fig. 10 Thermostat and Housing 2.5L VM Diesel
NOTE: Do not use any type of tool when tighten-
ing the cap. Hand tighten only (approximately 5 Nm
or 44 in. lbs.) torque.
COOLANT PERFORMANCE
ETHYLENE-GLYCOL MIXTURES
The requi red ethyl ene-gl ycol (anti freeze) and water
mi xture depends upon the cl i mate and vehi cl e oper-
ati ng condi ti ons. The recommended mi xture of 50/50
ethyl ene-gl ycol and water wi l l provi de protecti on
agai nst freezi ng to -37 deg. C (-35 deg. F). The anti -
freeze concentrati on must always be a mi ni mum of
44 percent, year-round i n al l cl i mates. If percentage
is lower than 44 percent, engine parts may be
eroded by cavitation, and cooling system com-
ponents may be severely damaged by corrosion.
Maxi mum protecti on agai nst freezi ng i s provi ded
wi th a 68 percent anti freeze concentrati on, whi ch
prevents freezi ng down to -67.7 deg. C (-90 deg. F). A
hi gher percentage wi l l freeze at a warmer tempera-
ture.
100 Percent Ethylene-Glycol Should Not Be Used in
Chrysler Vehicles
Use of 100 percent ethyl ene-gl ycol wi l l cause for-
mati on of addi ti ve deposi ts i n the system, as the cor-
rosi on i nhi bi ti ve addi ti ves i n ethyl ene-gl ycol requi re
the presence of water to di ssol ve. The deposi ts act as
i nsul ati on, causi ng temperatures to ri se to as hi gh as
149 deg. C (300) deg. F). Thi s temperature i s hot
enough to mel t pl asti c and soften sol der. The
i ncreased temperature can resul t i n engi ne detona-
ti on. I n addi ti on, 100 percent ethyl ene-gl ycol freezes
at 22 deg. C (-8 deg. F ).
Propylene-glycol Formulations Should Not Be Used in
Chrysler Vehicles
Propylene-glycol formulations do not meet
Chrysler coolant specifications. I ts overal l effec-
ti ve temperature range i s smal l er than that of ethyl -
ene-gl ycol . The freeze poi nt of 50/50 propyl ene-gl ycol
and water i s -32 deg. C (-26 deg. F). 5 deg. C hi gher
than ethyl ene-gl ycol s freeze poi nt. The boi l i ng poi nt
(protecti on agai nst summer boi l -over) of propyl ene-
gl ycol i s 125 deg. C (257 deg. F ) at 96.5 kPa (14 psi ),
compared to 128 deg. C (263 deg. F) for ethyl ene-gl y-
col . Use of propyl ene-gl ycol can resul t i n boi l -over or
freeze-up i n Chrysl er vehi cl es, whi ch are desi gned for
ethyl ene-gl ycol . Propyl ene gl ycol al so has poorer heat
transfer characteri sti cs than ethyl ene gl ycol . Thi s
can i ncrease cyl i nder head temperatures under cer-
tai n condi ti ons.
Propylene-glycol/Ethylene-glycol Mixtures Should Not Be
Used in Chrysler Vehicles
Propyl ene-gl ycol /ethyl ene-gl ycol Mi xtures can
cause the destabi l i zati on of vari ous corrosi on i nhi bi -
tors, causi ng damage to the vari ous cool i ng system
components. Al so, once ethyl ene-gl ycol and propy-
l ene-gl ycol based cool ants are mi xed i n the vehi cl e,
conventi onal methods of determi ni ng freeze poi nt wi l l
not be accurate. Both the refracti ve i ndex and spe-
ci fi c gravi ty di ffer between ethyl ene gl ycol and propy-
l ene gl ycol .
CAUTION: Richer antifreeze mixtures cannot be
measured with normal field equipment and can
cause problems associated with 100 percent ethyl-
ene-glycol.
BELT TENSION
Correct accessory dri ve bel t tensi on i s requi red to
be sure of opti mum performance of bel t dri ven engi ne
accessori es. I f speci fi ed tensi on i s not mai ntai ned,
bel t sl i ppage may cause; engi ne overheati ng, l ack of
power steeri ng assi st, l oss of ai r condi ti oni ng capac-
i ty, reduced generator output rate and greatl y
reduced bel t l i fe.
Fig. 11 Coolant Tank Pressure/Vent Cap
I ni ti al bel t adjustment i s done wi th a adjustabl e
tensi oner pul l ey. After the i ni ti al adjustment i s per-
formed, an automati c bel t tensi oner i s used to mai n-
tai n correct bel t tensi on at al l ti mes. Do not attempt
to check bel t tensi on wi th a bel t tensi on gauge on
vehi cl es equi pped wi th an automati c bel t tensi oner.
Refer to Automati c Bel t Tensi oner i n thi s group.
AUTOMATIC BELT TENSIONER
Dri ve bel t tensi on i s control l ed by a spri ng l oaded
automati c bel t tensi oner l ocated bel ow and to the
front of the engi ne oi l fi l ter (Fi g. 12). Thi s tensi oner
i s connected to a pi vot bracket and a pul l ey (Fi g. 12).
The pi vot bracket rotates on a pi vot pi n attached to
the engi ne. Speci al machi ned washers wi th rubber
o-ri ngs (Fi g. 12) are used at each si de of the pi vot
bracket to hel p keep di rt and water away from the
pi vot pi n.
I f a defecti ve bel t tensi oner i s suspected, a check of
thi s pi vot bracket and pi vot pi n shoul d be made. Cor-
rosi on may have formed at the pi n and may cause
the pi vot bracket to sti ck. Bel t sl i ppage wi l l resul t.
WARNING: BECAUSE OF HIGH SPRING PRES-
SURE, DO NOT ATTEMPT TO DISASSEMBLE THE
AUTOMATIC BELT TENSIONER. UNIT IS SERVICED
AS AN ASSEMBLY.
THERMOSTAT
DIAGNOSIS
Di esel engi nes, due to thei r i nherent effi ci ency are
sl ower to warm up than gasol i ne powered engi nes,
and wi l l operate at l ower temperatures when the
vehi cl e i s unl oaded. Because of thi s, l ower tempera-
ture gauge readi ngs for di esel versus gasol i ne
engi nes may, at ti mes be normal .
Typi cal l y, compl ai nts of l ow engi ne cool ant temper-
ature are observed as l ow heater output when com-
bi ned wi th cool or col d outsi de temperatures.
To hel p promote faster engi ne warm-up, an el ectri c
engi ne bl ock heater must be used wi th cool or col d
outsi de temperatures. Thi s wi l l hel p keep the engi ne
cool ant warm when the vehi cl e i s parked. Use the
bl ock heater i f the outsi de temperature i s bel ow 4C
(40F). Do not use the block heater if the out-
side temperature is above 4C (40F).
TESTING
NOTE: The DRB scan tool shoud be used to moni-
tor engine coolant temperature on the diesel
engine. Refer to the 1998 GS Powertrain Diagnostic
Manual for thermostat diagnosis procedure.
Fig. 12 Automatic Belt Tensioner Assembly
SERVICE PROCEDURES
ADDING ADDITIONAL COOLANT
2.5L VM DIESEL
Do not remove cool ant bottl e pressure cap when
the engi ne i s hot. Remove pressure cap and fi l l cool -
ant bottl e between Mi n and Max l i nes i nsi de fi l l er
neck. Use onl y 50/50 mi x of ethyl ene gl ycol type anti -
freeze and water (Fi g. 13). Squeezi ng radi ator hoses
may hel p purge ai r from the cool i ng system.
DRAINING COOLING SYSTEM
2.0L GASOLINE
To drai n cool i ng system move temperature sel ector
for heater to ful l heat wi th engi ne runni ng. Without
removing radiator pressure cap and with sys-
tem not under pressure, Shut engi ne off and open
drai ncock. The cool ant reserve tank shoul d empty
fi rst, then remove radi ator pressure cap and l et the
radi ator drai n (i f not, see Testi ng Cool i ng System for
l eaks).
2.5L VM DIESEL
The cool i ng system does not have a radi ator
mounted pressure cap. I nstead the pressure cap i s
mounted on the cool ant pressure bottl e (Fi g. 14).
(1) Shut off engi ne.
(2) Remove radi ator pressure cap.
(3) Open drai ncock and al l ow cool ant to drai n.
REFILLING COOLING SYSTEM
2.0L GASOLINE
Refer to the gasol i ne engi ne cool i ng system i nfor-
mati on i n thi s manual . Cool i ng system capaci ty i s 6.0
l i ters (6.34 qts.) whi ch i ncl udes the heater and cool -
ant recovery tank.
2.5L VM DIESEL
Fi rst cl ean system to remove ol d gl ycol , see Cool i ng
System Cl eani ng.
(1) Di sconnect upper radi ator hose at thermostat
housi ng.
(2) Remove pressure cap from cool ant expansi on
tank.
(3) Fi l l cool i ng system through upper radi ator hose
unti l cool ant starts to l eak out at the thermostat
housi ng. Reconnect hose and re-i nstal l cl amp.
(4) Fi l l expansi on tank to top of bottl e. Run engi ne
at i dl e wi thout pressure cap i nstal l ed for 5 mi nutes.
Squeeze upper radi ator hose several ti mes.
(5) Shut off engi ne. Top off cool ant and i nstal l
pressure cap.
(6) I nspect system for l eaks.
WATER PUMP 2. 0L GASOLINE
REMOVAL
(1) Remove accessory dri ve bel ts and power steer-
i ng pump.
(2) Drai n cool i ng system.
Fig. 13 Coolant Pressure Bottle2.5L VM Diesel
Fig. 14 Pressure Cap and BottleVM Diesel
(3) Remove power steeri ng pump bracket bol ts and
set pump and bracket assembl y asi de. Power steeri ng
l i nes do not need to be di sconnected.
(4) Remove ti mi ng bel t.
(5) Remove i nner ti mi ng bel t cover.
(6) Remove water pump attachi ng screws to engi ne
(Fi g. 15).
INSTALLATION
(1) I nstal l new O-ri ng gasket i n water pump body
O-ri ng groove (Fi g. 16). Use smal l dabs of Mopar Si l -
i cone Rubber Adhesi ve Seal ant around the water
pump body to secure O-ri ng i n pl ace duri ng i nstal l a-
ti on.
CAUTION: Make sure O-ring gasket is properly
seated in water pump groove before tightening
screws. An improperly located O-ring may cause
damage to the O-ring and cause a coolant leak.
(2) Assembl e pump body to bl ock and ti ghten
screws to 12 Nm (105 i n. l bs.). Pressuri ze cool i ng
system to 15 psi wi th pressure tester and check
water pump shaft seal and O-ri ng for l eaks.
movement.
(4) I nstal l i nner ti mi ng bel t cover.
(5) I nstal l ti mi ng bel t.
(6) Fi l l cool i ng system. See Filling Cooling Sys-
tem.
(7) I nstal l power steeri ng pump and accessory
dri ve bel ts.
WATER PUMP 2. 5L VM DIESEL
REMOVAL
i ng System i n thi s Group.
(2) Remove the ri ght i nner spl ash shi el d (Fi g. 17).
(3) Loosen the water pump pul l ey attachi ng bol ts
(Fi g. 18) before the accessory dri ve bel t i s removed.
(4) Loosen water pump accessory dri ve bel ts (Fi g.
19). Remove water pump pul l ey.
(5) Remove water pump attachi ng bol ts and
remove pump.
INSTALLATION
(1) I nstal l a new water pump to housi ng O-ri ng
gasket. I nstal l pump and ti ghten the attachi ng bol ts
to 22.6 Nm (205 i n. l bs.)
Fig. 15 Water Pump 2.0L Gasoline
Fig. 16 Water Pump Body 2.0L Gasoline
Fig. 17 Right Side Splash Shield
Fig. 18 Water Pump and Pulley 2.5 L VM Diesel
(2) I nstal l water pump pul l ey.
(3) I nstal l dri ve bel t, Refer to Accessory Dri ve
Bel ts, thi s Group. Ti ghten water pump pul l ey attach-
i ng bol ts to 27.5 Nm (240 i n. l bs.)
(4) I nstal l ri ght i nner spl ash shi el d.
(5) Refi l l cool i ng system. Refer to Refi l l i ng Cool i ng
System i n thi s Group.
ENGINE THERMOSTAT 2. 0L GASOLINE
REMOVAL
(1) Drai n cool i ng system to the thermostat l evel or
bel ow.
(2) Remove cool ant recovery system (CRS) hose
and thermostat/engi ne outl et connector bol ts.
(3) Remove thermostat and seal , and cl ean seal i ng
surfaces.
INSTALLATION
(1) Pl ace the new thermostat assembl y i nto the
thermostat housi ng/outl et connector. Al i gn ai r bl eed
vent wi th notch i n cyl i nder head.
(2) I nstal l thermostat housi ng/outl et connector
onto cyl i nder head and ti ghten bol ts to 12.5 Nm (110
i n. l bs.). Connect the upper radi ator hose.
(3) Refi l l cool i ng system (see Refilling System).
THERMOSTAT 2. 5L VM DIESEL
REMOVAL
secti on.
(2) Remove radi ator hose at thermostat cover.
(3) Remove thermostat cover bol ts (Fi g. 20).
(4) Remove Thermostat.
INSTALLATION
(1) Remove ol d gasket materi al from thermostat
housi ng and cover.
(2) I nstal l new thermostat gasket.
(3) I nstal l thermostat and ti ghten cover bol ts to
10.8 Nm (96 i n. l bs.).
(4) I nstal l radi ator hose.
(5) Refi l l cool i ng system. Refer to Refi l l i ng Cool i ng
System i n thi s secti on.
RADIATOR 2. 5L VM DIESEL
REMOVAL
(1) Di sconnect battery.
(2) Remove power steeri ng reservoi r attachi ng
bol ts, and reposi ti on reservoi r.
(3) Remove radi ator cl osure panel crossmember
(Fi g. 21).
(4) Remove ai r cl eaner housi ng and i ntake hose.
(5) Unpl ug fan modul e 4 pi n wi ri ng connector.
(6) Drai n cool i ng system. Refer to Drai ni ng cool i ng
system i n thi s secti on for procedure.
(7) Remove upper and l ower Radi ator Hoses.
(8) Remove radi ator attachi ng bol ts.
(9) Loosen A/C recei ver/dryer l ower bol t.
(10) Remove Radi ator.
(11) Remove fan modul e from radi ator.
Fig. 19 Water Pump Drive Belt 2.5 L VM Diesel
Fig. 20 Thermostat and Housing 2.5L VM Diesel
INSTALLATION
(1) I nstal l fan modul e on radi ator.
(2) I nstal l radi ator.
(3) Ti ghten recei ver/dryer l ower bol t.
(4) I nstal l radi ator attachi ng bol ts.
(5) I nstal l l ower and upper radi ator hoses.
(6) Connect fan modul e.
(7) I nstal l ai r cl eaner housi ng and i ntake hose.
(8) I nstal l radi ator cl osure panel crossmember.
(9) I nstal l power steeri ng reservoi r attachi ng bol ts.
(10) Refi l l cool i ng system. Refer to Refi l l i ng cool i ng
system i n thi s secti on for procedure.
(11) Connect battery.
WATER PUMP BELT 2. 5L VM DIESEL
REMOVAL
(1) Remove generator/power steeri ng bel t. Refer to
(3) Remove ri ght si de spl ash shi el d (Fi g. 22).
(4) Loosen bel t tensi oner bracket bol ts (Fi g. 23).
(5) Loosen adjuster l ock nut.
(6) Loosen adjusti ng bol t, and remove bel t.
INSTALLATION
(1) I nstal l water pump bel t.
(2) Turn adjusti ng bol t cl ockwi se to ti ghten bel t.
(3) Ti ghten l ock nut.
(4) Ti ghten bel t tensi oner bracket bol ts
(6) I nstal l generator/power steeri ng bel t. Refer to
GENERATOR/POWER STEERING BELT 2. 5L VM
DIESEL
REMOVAL
(1) Loosen generator pi vot bol t (Fi g. 24).
(2) Loosen adjusti ng bracket bol t.
(3) Loosen adjusti ng nut.
(4) Remove generator/power steeri ng bel t.
INSTALLATION
(1) I nstal l generator/power steeri ng bel t.
(2) Ti ghten adjusti ng nut.
(3) Ti ghten adjusti ng bracket bol t.
(4) Ti ghten generator pi vot bol t.
WATER PUMP
i ng defects.
Fig. 21 Radiator Closure Panel Crossmember
Fig. 23 Water Pump Belt Removal 2.5L VM Diesel
(2) Cool ant l eaks; i f the seal i s l eaki ng, thi s wi l l be
evi dent by traces of thi ck deposi ts of greeni sh-brown
dri ed gl ycol runni ng down the pump body and com-
ponents bel ow. A thi n bl ack stai n bel ow pump weep
hol e i s consi dered normal operati on.
(3) I mpel l er rubs i nsi de of the cyl i nder bl ock 2.0L
engi ne. I mpel l er rubs i nsi de of the water pump hous-
i ng 2.5L VM di esel engi ne.
(4) Excessi vel y l oose or rough turni ng beari ng.
NOTE: It is normal for the water pump to weep a
small amount of coolant from the weep hole (black
stain on water pump body). Do not replace the
water pump if this condition exists. Replace the
water pump if a heavy deposit or a steady flow of
green/brown engine coolant is evident on water
pump body from the weep hole (shaft seal failure).
Be sure to perform a thorough analysis before
replacing water pump.
ADJ USTMENTS
BELT TENSION GAUGE METHOD
Use bel t tensi oni ng Speci al Tool Ki t C-4162 for:
CAUTION: The Burroughs gauge for the Poly-V
belt is not to be used on the V-belt. These gauges
are not interchangeable.
For conventi onal V-bel ts affi x the Burroughs
gauge (Speci al Tool C-4162) to the bel t. Adjust the
bel t tensi on for New or Used bel t as prescri bed i n the
Bel t Tensi on Chart. For a Pol y-V bel t affi x the Pol y-V
Burroughs gauge to the bel t and then appl y speci fi ed
tensi on to the bel t as prescri bed i n the Bel t Tensi on
Chart
Adjust the bel t tensi on for a New or Used bel t as
prescri bed i n the Bel t Tensi on Chart.
BELT TENSION CHART
Fig. 24 Generator/Power Steering Removal 2.5L
VM Diesel
ACCESSORY DRIVE
BELT
GAUGE
2.0L GASOLINE ENGINE
GENERATOR AND AIR
CONDITIONING
NEW 667 44 N (150
10 LBS).
USED 556 N (125 LBS.)
POWER STEERING NEW 578 44 N (130
10 LBS).
USED 489 N (110 LBS).
2.5L VM DIESEL
WATER PUMP NEW N/A LBS.
USED N/A LBS.
GENERATOR /AIR
CONDITIONING/
POWER STEERING
NEW 667 44 N (150
10 LBS).
USED 556 N (125 LBS).
SPECIFICATIONS
COOLING SYSTEM CAPACITY
TORQUE CHART
SPECIAL TOOLS
COOLING
2.0L Gasoline *10.6 liters (11 qts.)
2.5L VM Diesel *10.0 liters (10.6 qts.)
*Includes Heater and Coolant recovery/pressure Tank.
COMPONENT 2.0L
GASOLINE
2.5L VM
Thermostat
Cover Bolts
105 in-lbs 10.8 Nm (96 in.
lbs.)
Water Pump
Mounting Bolts
12 Nm (105 in.
lbs.)
22.6 Nm (204
in. lbs.)
Water Pump
Pulley Bolts
N/A 27.5 Nm (240
in. lbs.)
Upper Radiator
Mounting
Bracket Bolts
12 Nm (105 in.
lbs.)
12 Nm (105 in.
lbs.)
Turbocharger
Oil Supply Line
N/A 24.5 Nm (215
in. lbs.)
Turbocharger
Oil Return Line
N/A 10.8 Nm (96 in.
lbs.)
Water Pump
Housing Nuts
N/A 9.5 Nm (84 in.
lbs.)
Water Manifold
Bolts
N/A 11.2 Nm (96 in.
lbs.)
Coolant Bottle
Bolts
2.0 Nm (18 in.
lbs.)
10.8 Nm (96 in.
lbs.)
Belt Tension Gauge C-4162
BATTERY
CONTENTS
page page
GENERAL INFORMATION
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . 1
SAFETY PRECAUTIONS AND WARNINGS . . . . . 1
BATTERY IGNITION OFF DRAW (IOD) . . . . . . . . 1
CHARGING TIME REQUIRED . . . . . . . . . . . . . . . 2
BATTERY BUILT-IN TEST INDICATOR . . . . . . . . 2
BATTERY IGNITION OFF DRAW (IOD) . . . . . . . . 3
BATTERY LOAD TEST . . . . . . . . . . . . . . . . . . . . . 4
BATTERY OPEN CIRCUIT VOLTAGE TEST . . . . . 6
SERVICE PROCEDURES
BATTERY CHARGING . . . . . . . . . . . . . . . . . . . . . 6
CHARGING COMPLETELY DISCHARGED
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
VISUAL INSPECTION . . . . . . . . . . . . . . . . . . . . . 7
BATTERY TRAY . . . . . . . . . . . . . . . . . . . . . . . . . . 9
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SPECIFICATIONS
BATTERY SPECIFICATIONS . . . . . . . . . . . . . . . 10
TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
GENERAL INFORMATION
INTRODUCTION
The battery stores, stabi l i zes, and del i vers el ectri -
cal current to operate vari ous el ectri cal systems i n
the vehi cl e. The determi nati on of whether a battery
i s good or bad i s made by i ts abi l i ty to accept a
charge. I t al so must suppl y hi gh-amperage current
for a l ong enough peri od to be abl e to start the vehi -
cl e. The capabi l i ty of the battery to store el ectri cal
current comes from a chemi cal reacti on. Thi s reac-
ti on takes pl ace between the sul furi c aci d sol uti on
(el ectrol yte) and the l ead +/- pl ates i n each cel l of the
battery. As the battery di scharges, the pl ates react
wi th the aci d from the el ectrol yte. When the chargi ng
system charges the battery, the water i s converted to
sul furi c aci d i n the battery. The concentrati on of aci d
i n the el ectrol yte i s measured as speci fi c gravi ty
usi ng a hydrometer. The ori gi nal equi pment (OE)
battery i s equi pped wi th a hydrometer (test i ndi ca-
tor) bui l t i nto the battery cover. The speci fi c gravi ty
i ndi cates the batterys state-of-charge. The OE bat-
tery i s seal ed and water cannot be added.
The battery i s vented to rel ease gases that are cre-
ated when the battery i s bei ng charged and di s-
charged. The battery top, posts, and termi nal s shoul d
be cl eaned when other under hood mai ntenance i s
performed.
When the el ectrol yte l evel i s bel ow the top of the
pl ates, Cl ear i n the test I ndi cator, the battery must
be repl aced. The battery must be compl etel y charged,
and the battery top, posts, and cabl e cl amps must be
cl eaned before di agnosti c procedures are performed.
SAFETY PRECAUTIONS AND WARNINGS
WARNING: DO NOT ALLOW JUMPER CABLE
CLAMPS TO TOUCH EACH OTHER WHEN CON-
NECTED TO A BOOSTER SOURCE. DO NOT USE
OPEN FLAME NEAR BATTERY. REMOVE METALLIC
JEWELRY WORN ON HANDS OR WRISTS TO AVOID
INJURY BY ACCIDENTAL ARCING OF BATTERY
CURRENT.
WHEN USING A HIGH OUTPUT BOOSTING DEVICE,
DO NOT ALLOW THE DISABLED VEHICLES BAT-
TERY TO EXCEED 16 VOLTS. PERSONAL INJURY
OR DAMAGE TO ELECTRICAL SYSTEM CAN
RESULT.
TO PROTECT THE HANDS FROM BATTERY ACID, A
SUITABLE PAIR OF HEAVY DUTY RUBBER
GLOVES, NOT THE HOUSEHOLD TYPE, SHOULD
BE WORN WHEN REMOVING OR SERVICING A
BATTERY. SAFETY GLASSES ALSO SHOULD BE
WORN.
BATTERY IGNITION OFF DRAW (IOD)
A compl etel y normal vehi cl e wi l l have a smal l
amount of current drai n on the battery wi th the key
out of the i gni ti on. I t can range from 5 to 25 mi l l i -
amperes after al l the modul es ti me out. I f a vehi cl e
wi l l not be operated for approxi matel y a 20 days, the
I OD fuse shoul d be pul l ed to el i mi nate the vehi cl e
el ectri cal drai n on the battery. The I OD fuse i s
NS BATTERY 8A - 1
l ocated i n the Power Di stri buti on Center (PDC).
Refer to the PDC cover for proper fuse.
CHARGING TIME REQUIRED
WARNING: NEVER EXCEED 20 AMPS WHEN
CHARGING A COLD -1C (30F) BATTERY. PER-
SONAL INJURY MAY RESULT.
The ti me requi red to charge a battery wi l l vary
dependi ng upon the fol l owi ng factors.
SIZE OF BATTERY
A compl etel y di scharged l arge heavy-duty battery
may requi re more rechargi ng ti me than a compl etel y
di scharged smal l capaci ty battery, refer to the Bat-
tery Chargi ng Ti metabl e for chargi ng ti mes.
TEMPERATURE
A l onger ti me wi l l be needed to charge a battery at
-18C (0F) than at 27C (80F). When a fast charger
i s connected to a col d battery, current accepted by
battery wi l l be very l ow at fi rst. I n ti me, the battery
wi l l accept a hi gher rate as battery temperature
warms.
CHARGER CAPACITY
A charger whi ch can suppl y onl y fi ve amperes wi l l
requi re a much l onger peri od of chargi ng than a
charger that can suppl y 20 amperes or more.
STATE OF CHARGE
A compl etel y di scharged battery requi res more
chargi ng ti me than a parti al l y charged battery. El ec-
trol yte i s nearl y pure water i n a compl etel y di s-
charged battery. At fi rst, the chargi ng current
amperage wi l l be l ow. As water i s converted back to
sul furi c aci d i nsi de the battery, the current amp rate
wi l l ri se. Al so, the speci fi c gravi ty of the el ectrol yte
wi l l ri se, bri ngi ng the green bal l (Fi g. 1) i nto vi ew at
approxi matel y 75 percent state-of-charge.
BATTERY BUILT-IN TEST INDICATOR
USING TEST INDICATOR
The Test I ndi cator (Fi g. 1), (Fi g. 2) and (Fi g. 3)
measures the speci fi c gravi ty of the el ectrol yte. Spe-
ci fi c Gravi ty (SG) of the el ectrol yte wi l l show state-
of-charge (vol tage). The test i ndi cator WI LL NOT
show cranki ng capaci ty of the battery. Refer to Bat-
tery Load Test for more i nformati on. Look i nto the
si ght gl ass (Fi g. 1), (Fi g. 3) and note the col or of the
i ndi cator. Refer to the fol l owi ng descri pti on of col ors:
NOTE: GREEN = 75 to 100% state-of-charge
The battery i s adequatel y charged for further test-
i ng and may be returned to use. I f the vehi cl e wi l l
not crank for a maxi mum 15 seconds, refer to BAT-
TERY LOAD TEST i n thi s Group for more i nforma-
ti on.
NOTE: BLACK OR DARK = 0 to 75% state-of-charge
The battery i s I NADEQUATELY charged and must
be charged unti l green dot i s vi si bl e, (12.4 vol ts or
greater) before the battery i s tested or returned to
BATTERY CHARGING TIMETABLE
Charging
Amperage
5
Amperes
10
Amperes
20
Amperes
Open Circuit
Voltage
Hours Charging at 21C (70F)
12.25 to 12.39 6 hours 3 hours 1.5 hours
12.00 to 12.24 8 hours 4 hours 2 hours
11.95 to 11.99 12 hours 6 hours 3 hours
10.00 to 11.94 14 hours 7 hours 3.5 hours
less than 10.00 See Charging Completely
Discharged Battery
Fig. 1 Reading Test Indicator
Fig. 2 Battery Construction and Test Indicator
8A - 2 BATTERY NS
use. Refer to Causes of Battery Di schargi ng i n thi s
Group for more i nformati on.
NOTE: CLEAR COLOR = Replace Battery
WARNING: DO NOT CHARGE, ASSIST BOOST,
LOAD TEST, OR ADD WATER TO THE BATTERY
WHEN CLEAR COLOR DOT IS VISIBLE. PERSONAL
INJURY MAY OCCUR.
A cl ear col or dot shows el ectrol yte l evel i n battery
i s bel ow the test i ndi cator (Fi g. 1). Water cannot be
added to a mai ntenance free battery. The battery
must be repl aced. A l ow el ectrol yte l evel may be
caused by an over chargi ng condi ti on. Refer to Gen-
erator Test Procedures on Vehi cl e.
CAUSES OF BATTERY DISCHARGING
I t i s normal to have a smal l 5 to 25 mi l l i amperes
conti nuous el ectri cal draw from the battery. Thi s
draw wi l l take pl ace wi th the i gni ti on i n the OFF
posi ti on, and the courtesy, dome, storage compart-
ments, and engi ne compartment l i ghts OFF. The con-
ti nuous draw i s due to vari ous el ectroni c features or
accessori es that requi re el ectri cal current wi th the
i gni ti on OFF to functi on properl y. When a vehi cl e i s
not used over an extended peri od of approxi matel y 20
days the I OD fuse shoul d be pul l ed. The fuse i s
l ocated i n the power di stri buti on center. Di sconnec-
ti on of thi s fuse wi l l reduce the l evel of battery di s-
charge. Refer to Battery Di agnosi s and Testi ng tabl e
and to the proper procedures.
ABNORMAL BATTERY DISCHARGING
Corroded battery posts, cabl es or termi nal s.
Loose or worn generator dri ve bel t.
El ectri cal l oads that exceed the output of the
chargi ng system due to equi pment or accessori es
i nstal l ed after del i very.
Sl ow dri vi ng speeds i n heavy traffi c condi ti ons
or prol onged i dl i ng wi th hi gh-amperage el ectri cal
systems i n use.
Defecti ve el ectri cal ci rcui t or component causi ng
excess I gni ti on Off Draw (I OD). Refer to Battery
I gni ti on Off Draw (I OD).
Defecti ve chargi ng system.
Defecti ve battery.
Hi gh current draw on the battery wi th the i gni ti on
OFF wi l l di scharge a battery. After a dead battery i s
servi ced the vehi cl e I gni ti on Off Draw (I OD) shoul d
be checked. Determi ne i f a hi gh current draw condi -
ti on exi sts fi rst check the vehi cl e wi th a test l amp.
(1) Veri fy that al l el ectri cal accessori es are OFF.
Remove key from i gni ti on swi tch
Turn off al l l i ghts
Li ftgate and gl ove box door i s cl osed
Sun vi sor vani ty l i ghts are OFF
Al l doors are cl osed
Al l ow the I l l umi nated Entry System to ti me out
i n approxi matel y 30 seconds, i f equi pped.
Duri ng Transmi ssi on Control Modul e (TCM)
power down there wi l l be 500 mi l l i amperes present
for 20 mi nutes. Afterwards l ess than 1.0 mi l l i ampere.
(2) Di sconnect battery negati ve cabl e (Fi g. 4).
CAUTION: Always disconnect the meter before
opening a door.
(3) Usi ng an mul ti meter, that has l east a mi l l i am-
pere range of 200 mA. Set meter to the hi ghest mA
range. I nstal l meter between the battery negati ve
cabl e and battery negati ve post (Fi g. 5). Careful l y
remove the test l amp wi thout di sconnecti ng the
meter. After al l modul es ti me-out the total vehi cl e
I OD shoul d be l ess than 25 mi l l i amperes. I f i gni ti on
off draw i s more than 25 mi l l i amperes go to Step 4.
(4) Each ti me the test l amp or mi l l i ampere meter
i s di sconnected and connected, al l el ectroni c ti mer
functi ons wi l l be acti vated for approxi matel y one
mi nute. The Body Control Modul e (BCM) i gni ti on off
draw can reach 90 mi l l i amperes.
(5) Remove the PDC fuses:
I nteri or l amps
Brake l amp
I OD
(6) I f there i s any readi ng, wi th fuses removed
there i s a short ci rcui t i n the wi ri ng. Refer to Group
8W, wi ri ng di agrams. I f readi ng i s l ess than 25 mA
go to Step 8.
(7) I nstal l al l fuses. After i nstal l i ng fuse, the cur-
rent can reach 90 mA. After ti me-out the readi ng
shoul d not exceed 25 mA. I f OK go to. I f not, di scon-
nect:
Radi o
Body Control Modul e
Remote Keyl ess Entry Modul e
Fig. 3 Test Indicator
NS BATTERY 8A - 3
(8) Di sconnect one component at ti me, to see i f any
component i s at faul t. I f the hi gh readi ng i s not el i m-
i nated there i s a short ci rcui t i n the wi ri ng. Refer to
Group 8W, wi ri ng di agrams.
(9) Remove i nteri or and brake l amp fuses. I nstal l
the fuses. The mi l l i ampere readi ng shoul d be 2-4 mA.
I f readi ng i s hi gher than 4 mA:
(a) Di sconnect PCM.
(b) I f readi ng i s OK, repl ace PCM.
(c) I f readi ng does not change, di sconnect the
TCM.
(d) I f readi ng i s OK, repl ace TCM.
(e) I f readi ng stays, there i s a short ci rcui t to
one of the modul es. Refer to Group 8W, Wi ri ng
Di agrams.
BATTERY LOAD TEST
A ful l y charged battery must have cranki ng capac-
i ty, to provi de the starter motor and i gni ti on system
enough power to start the engi ne over a broad range
of ambi ent temperatures. A battery l oad test wi l l ver-
i fy the actual cranki ng capabi l i ty of the battery.
WARNING: IF BATTERY SHOWS SIGNS OF FREEZ-
ING, LEAKING, LOOSE POSTS, OR EXCESSIVELY
LOW ELECTROLYTE LEVEL, DO NOT TEST. ACID
BURNS OR AN EXPLOSIVE CONDITION MAY
RESULT.
(1) Remove both battery cabl es, negati ve cabl e
fi rst. The battery top, cabl es and posts shoul d be
BATTERY DIAGNOSIS AND TESTING
STEPS POSSIBLE CAUSE CORRECTION
VISUAL INSPECTION
Check for possible damage to
battery and clean battery.
(1) Loose battery post, Cracked
battery cover or case, Leaks or Any
other physical
(2) Battery OK.
(1) Replace Battery
(2) Check state of charge. Refer to
Test Indicator.
TEST INDICATOR
Check Charge Eye Color
(1) GREEN
(2) BLACK
(3) CLEAR
(1) Battery is charged. Perform
Battery 0pen Circuit Voltage Test
(2) Perform Battery Charging
procedure.
(3) Replace Battery.
BATTERY OPEN CIRCUIT
VOLTAGE TEST
(1) Battery is above 12.40 Volts
(2) Battery is below 12.40 Volts.
(1) Perform the Battery Load Test.
procedure.
BATTERY CHARGING (1) Battery accepted Charge.
(2) Battery will not accept charge
(1) Ensure that the indicator eye is
GREEN and perform Battery 0pen
Circuit Voltage Test
(2) Perform Charging a Completely
Discharged Battery.
BATTERY LOAD TEST (1) Acceptable minimum voltage.
(2) Unacceptable minimum voltage
(1) Battery is OK to put in use,
perform Battery Ignition Off Draw
Test.
(2) Replace Battery and perform
Battery Ignition Off Draw Test.
CHARGING A COMPLETELY
DISCHARGED BATTERY
(1) Battery accepted charge.
(2) Battery will not accept charge.
(1) Ensure that the indicator eye is
GREEN and perform Battery 0pen
Circuit Voltage Test.
IGNITION OFF DRAW TEST (1) IOD is 5-25 Milliamperes.
(2) IOD Exceeds 25 Milliamperes.
(1) Vehicle is normal.
(2) Eliminate excess IOD draw.
Fig. 4 Disconnect Battery Negative Cable
8A - 4 BATTERY NS
cl ean. I f green dot i s not vi si bl e i n i ndi cator, charge
the battery. Refer to Battery Chargi ng Procedures.
(2) Connect a Vol t/Ammeter/Load tester to the bat-
tery posts (Fi g. 6). Rotate the l oad control knob of the
Carbon pi l e rheostat to appl y a 300 amp l oad. Appl y
thi s l oad for 15 seconds to remove the surface charge
from the battery, and return the control knob to off
(Fi g. 7).
(3) Al l ow the battery to stabi l i ze for 2 mi nutes,
and then veri fy open ci rcui t vol tage.
(4) Rotate the l oad control knob on the tester to
mai ntai n 50% of the battery col d crank rati ng for 15
seconds (Fi g. 8). Record the l oaded vol tage readi ng
and return the l oad control to off. Refer to the Bat-
tery Speci fi cati ons at the rear of thi s Group.
(5) Vol tage drop wi l l vary accordi ng to battery
temperature at the ti me of the l oad test. Battery
temperature can be esti mated by the temperature of
exposure over the precedi ng several hours. I f the bat-
tery has been charged or boosted a few mi nutes pri or
to the test, the battery woul d be sl i ghtl y warmer.
Refer to Battery Load Test Temperature Tabl e:
(6) I f battery passes l oad test, i t i s i n good condi -
ti on and further tests are not necessary. I f i t fai l s
l oad test, i t shoul d be repl aced.
Fig. 5 Milliampere Meter Connection
Fig. 6 Volt-Ammeter Load Tester Connections
Fig. 7 Remove Surface Charge From Battery
Fig. 8 Load 50% Cold Crank Rating
BATTERY LOAD TEST TEMPERATURE
Minimum Voltage
Temperature
F C
9.6 volts 70and above 21and above
9.5 volts 60 16
9.4 volts 50 10
9.3 volts 40 4
9.1 volts 30 -1
8.9 volts 20 -7
8.7 volts 10 -12
8.5 volts 0 -18
NS BATTERY 8A - 5
BATTERY OPEN CIRCUIT VOLTAGE TEST
An open ci rcui t vol tage no l oad test shows the
state of charge of a battery and whether i t i s ready
for a l oad test at 50 percent of the batterys col d
crank rati ng. Refer to Battery Load Test. I f a battery
has open ci rcui t vol tage readi ng of 12.4 vol ts or
greater, and wi l l not pass the l oad test, repl ace the
battery because i t i s defecti ve. To test open ci rcui t
vol tage, perform the fol l owi ng operati on.
fi rst. Battery top, cabl es and posts shoul d be cl ean. I f
green dot i s not vi si bl e i n i ndi cator, charge the bat-
tery. Refer to Battery Chargi ng Procedures.
(Fi g. 7).
and then veri fy the open ci rcui t vol tage (Fi g. 9).
(4) Thi s vol tage readi ng wi l l approxi mate the state
of charge of the battery. I t wi l l not reveal battery
cranki ng capaci ty. Refer to Battery Open Ci rcui t
Vol tage tabl e.
SERVICE PROCEDURES
BATTERY CHARGING
WARNING: DO NOT CHARGE A BATTERY THAT
HAS EXCESSIVELY LOW ELECTROLYTE LEVEL.
BATTERY MAY SPARK INTERNALLY AND
EXPLODE. EXPLOSIVE GASES FORM OVER THE
BATTERY. DO NOT SMOKE, USE FLAME, OR CRE-
ATE SPARKS NEAR BATTERY. DO NOT ASSIST
BOOST OR CHARGE A FROZEN BATTERY. BAT-
TERY CASING MAY FRACTURE. BATTERY ACID IS
POISON, AND MAY CAUSE SEVERE BURNS. BAT-
TERIES CONTAIN SULFURIC ACID. AVOID CON-
TACT WITH SKIN, EYES, OR CLOTHING. IN THE
EVENT OF CONTACT, FLUSH WITH WATER AND
CALL PHYSICIAN IMMEDIATELY. KEEP OUT OF
REACH OF CHILDREN.
CAUTION: Disconnect the battery NEGATIVE cable
first. (Fig. 4) before charging battery to avoid dam-
age to electrical systems. Do not exceed 16.0 volts
while charging battery. Refer to the instructions
supplied with charging equipment
NOTE: The battery cannot be refilled with water, it
must be replaced.
A battery i s consi dered ful l y charged when i t wi l l
meet al l the fol l owi ng requi rements.
I t has an open ci rcui t vol tage charge of at l east
12.4 vol ts.
I t passes the 15 second l oad test, refer to the
Load Test Temperature chart.
The bui l t i n test i ndi cator dot i s GREEN (Fi g.
1).
Battery el ectrol yte wi l l bubbl e i nsi de of battery
case whi l e bei ng charged properl y. I f the el ectrol yte
boi l s vi ol entl y, or i s di scharged from the vent hol es
whi l e chargi ng, i mmedi atel y reduce chargi ng rate or
turn off charger. Eval uate battery condi ti on. Battery
damage may occur i f chargi ng i s excessi ve.
Some battery chargers are equi pped wi th pol ari ty
sensi ng devi ces to protect the charger or battery from
bei ng damaged i f i mproperl y connected. I f the bat-
tery state of charge i s too l ow for the pol ari ty sensor
to detect, the sensor must be bypassed for charger to
operate. Refer to operati ng i nstructi ons provi ded
wi th battery charger bei ng used.
CAUTION: Charge battery until test indicator
appears green. Do not overcharge.
I t may be necessary to ji ggl e the battery or vehi cl e
to bri ng the green dot i n the test i ndi cator i nto vi ew.
Fig. 9 Testing Open Circuit Voltage
BATTERY OPEN CIRCUIT VOLTAGE
Open Circuit Volts
Charge Per-
centage
11.7 volts or less 0%
12.0 volts 25%
12.2 volts 50%
12.4 volts 75%
12.6 volts or more 100%
8A - 6 BATTERY NS
After the battery has been charged to 12.4 vol ts or
greater, perform a l oad test to determi ne cranki ng
capaci ty. Refer to Battery Load Test i n thi s Group. I f
the battery passes the l oad test, return the battery to
use. I f battery wi l l not endure a l oad test, i t must be
repl aced. Properl y cl ean and i nspect battery hol d
downs, tray, termi nal s, cabl es, posts, and top before
compl eti ng servi ce.
CHARGING COMPLETELY DISCHARGED BATTERY
The fol l owi ng procedure shoul d be used to recharge
a compl etel y di scharged battery. Unl ess procedure i s
properl y fol l owed, a good battery may be needl essl y
repl aced. Refer to Battery Chargi ng Rate tabl e.
(1) Measure the vol tage at battery posts wi th a
vol tmeter accurate to 1/10 vol t (Fi g. 10). I f bel ow 10
vol ts, charge current wi l l be l ow, and i t coul d take
some ti me before i t accepts a current i n excess of a
few mi l l i amperes. Such l ow current may not be
detectabl e on amp meters bui l t i nto many chargers.
(2) Connect charger l eads. Some chargers feature
pol ari ty protecti on ci rcui try that prevents operati on
unl ess charger i s connected to battery posts correctl y.
A compl etel y di scharged battery may not have
enough vol tage to acti vate thi s ci rcui try. Thi s may
happen even though the l eads are connected properl y.
(3) Battery chargers vary i n the amount of vol tage
and current they provi de. For the ti me requi red for
the battery to accept measurabl e charger current at
vari ous vol tages, refer to Battery Chargi ng Rate
tabl e. I f charge current i s sti l l not measurabl e after
chargi ng ti mes, the battery shoul d be repl aced. I f
charge current i s measurabl e duri ng chargi ng ti me,
the battery may be good, and chargi ng shoul d be
compl eted i n the normal manner.
VISUAL INSPECTION
CAUTION: Do not allow baking soda solution to
enter vent holes, as damage to battery can result.
(1) Cl ean top of battery wi th a sol uti on of warm
water and baki ng soda.
(2) Appl y soda sol uti on wi th a bri stl e brush and
al l ow to soak unti l aci d deposi ts l oosen (Fi g. 11).
(3) Ri nse soda sol uti on from battery wi th cl ear
water and bl ot battery dry wi th paper towel i ng. Di s-
pose of towel i ng i n a safe manner. Refer to the
WARNI NGS on top of battery.
(4) I nspect battery case and cover for cracks, l eak-
age or damaged hol d down l edge. I f battery i s dam-
aged repl ace i t.
(5) I nspect battery tray for damage caused by aci d
from battery. I f aci d i s present, cl ean area wi th bak-
i ng soda sol uti on.
(6) Cl ean battery posts wi th a battery post cl ean-
i ng tool (Fi g. 12).
(7) Cl ean battery cabl e cl amps wi th a battery ter-
mi nal cl eani ng tool (Fi g. 13). Repl ace cabl es that are
frayed or have broken cl amps.
BATTERY CHARGING RATE
Voltage Hours
16.0 volts maximum up to 4 hours
14.0 to 15.9 volts up to 8 hours
13.9 volts or less up to 16 hours
Fig. 10 Voltmeter Accurate to 1/10 Volt (Connected)
Fig. 11 Cleaning Battery
NS BATTERY 8A - 7
BATTERY
WARNING: TO PROTECT THE HANDS FROM BAT-
TERY ACID, A SUITABLE PAIR OF HEAVY DUTY
RUBBER GLOVES, NOT THE HOUSEHOLD TYPE,
SHOULD BE WORN WHEN REMOVING OR SERVIC-
ING A BATTERY. SAFETY GLASSES ALSO SHOULD
BE WORN.
REMOVAL
(1) Veri fy that the i gni ti on swi tch and al l accesso-
ri es are OFF.
(2) Di sconnect battery cabl e termi nal s from the
battery posts, negati ve fi rst (Fi g. 14).
(3) Remove battery heat shi el d (Fi g. 15).
(4) Remove battery hol d down (Fi g. 16).
(5) Remove battery from vehi cl e (Fi g. 17).
INSTALLATION
I nspect and cl ean battery and attachi ng compo-
nents before i nstal l ati on.
(1) I nstal l battery i n vehi cl e maki ng sure that bat-
tery i s properl y posi ti oned on battery tray.
(2) I nstal l battery hol d down.
Fig. 12 Cleaning Battery Post
Fig. 13 Cleaning Battery Cable Terminal
Fig. 14 Battery Cable Disconnected
Fig. 15 Battery Heat Shield
8A - 8 BATTERY NS
(3) Pl ace battery heat shi el d over battery. The top
i nsi de surface of heat shi el d must be fl ush wi th top
of battery.
(4) Connect battery cabl e termi nal s, posi ti ve cabl e
fi rst. Make sure the top of battery termi nal s are
fl ush wi th top of posts.
WARNING: DO NOT OVER TIGHTEN BATTERY
CABLE CLAMPS, DAMAGE TO CLAMPS CAN
RESULT.
(5) Ti ghten termi nal nuts to 8.5 Nm (75 i n. l bs.).
BATTERY TRAY
REMOVAL
(1) Remove battery, refer to the above procedures.
(2) Remove nut and two bol ts from battery tray
(Fi g. 18).
(3) Remove battery tray from vehi cl e.
(4) Remove speed control servo attachi ng bol t from
battery tray (i f equi pped). Use care when di sconnect-
i ng vacuum l i nes from reservoi r (Fi g. 19).
INSTALLATION
For i nstal l ati on, reverse the above procedures.
Fig. 16 Battery Hold Down
Fig. 17 Remove Battery
Fig. 18 Battery Tray Removal
NS BATTERY 8A - 9
SPECIFICATIONS
BATTERY SPECIFICATIONS
CRANKING RATING
The current battery can del i ver for 30 seconds and
mai ntai n a termi nal vol tage of 7.2 vol ts or greater at
speci fi ed temperature.
RESERVE CAPACITY RATING
The l ength of ti me a battery can del i ver 25 amps
and mai ntai n a mi ni mum termi nal vol tage of 10.5
vol ts at 27C (80F).
TORQUE
DESCRIPTION TORQUE
Battery Hol d Down Bol t Cl amp
Bol t . . . . . . . . . . . . . . . . . . . .14 Nm (125 i n. l bs.)
Fig. 19 Speed Control Servo Removal
Load Test
(Amps)
Cold Cranking
Rating @ 0F
Reserve
Capacity
250 Amp 500 Amp 110 Minutes
8A - 10 BATTERY NS
BATTERY
CONTENTS
page page
GENERAL INFORMATION
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . 1
SAFETY PRECAUTIONS AND WARNINGS . . . . 1
BATTERY IGNITION OFF DRAW (IOD) . . . . . . . 2
CHARGING TIME REQUIRED . . . . . . . . . . . . . . 2
BATTERY DISCHARGING . . . . . . . . . . . . . . . . . 3
BATTERY IGNITION OFF DRAW . . . . . . . . . . . . 3
BATTERY LOAD TEST . . . . . . . . . . . . . . . . . . . 5
BATTERY OPEN CIRCUIT VOLTAGE TEST . . . . 6
SERVICE PROCEDURES
BATTERY CHARGING . . . . . . . . . . . . . . . . . . . . 6
CHARGING COMPLETELY DISCHARGED
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
VISUAL INSPECTION . . . . . . . . . . . . . . . . . . . . 7
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
BATTERY TRAY . . . . . . . . . . . . . . . . . . . . . . . . 9
SPECIFICATIONS
BATTERY SPECIFICATIONS . . . . . . . . . . . . . . . 9
TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
GENERAL INFORMATION
INTRODUCTION
The battery stores, stabi l i zes, and del i vers el ectri -
cal current to operate vari ous el ectri cal systems i n
the vehi cl e (Fi g. 1). The determi nati on of whether a
battery i s good or bad i s made by i ts abi l i ty to accept
a charge. I t al so must suppl y hi gh-amperage current
for a l ong enough peri od to be abl e to start the vehi -
cl e. The capabi l i ty of the battery to store el ectri cal
current comes from a chemi cal reacti on. Thi s reac-
ti on takes pl ace between the sul furi c aci d sol uti on
(el ectrol yte) and the l ead +/- pl ates i n each cel l of the
battery. As the battery di scharges, the pl ates react
wi th the aci d from the el ectrol yte. When the chargi ng
system charges the battery, the water i s converted to
sul furi c aci d i n the battery. The concentrati on of aci d
i n the el ectrol yte i s measured as speci fi c gravi ty
usi ng a hydrometer. The speci fi c gravi ty i ndi cates the
batterys state-of-charge.
The battery i s vented to rel ease gases that are cre-
ated when the battery i s bei ng charged and di s-
charged.
The battery top, posts, and termi nal s shoul d be
cl eaned when other under hood mai ntenance i s per-
formed.
The battery top, posts, cabl e cl amps must be
cl eaned and battery must be compl etel y charged
before di agnosti c procedures are performed.
WARNING:
DO NOT ALLOW JUMPER CABLE CLAMPS TO
TOUCH EACH OTHER WHEN CONNECTED TO A
BOOSTER SOURCE.
DO NOT USE OPEN FLAME NEAR BATTERY.
REMOVE METALLI C JEWELRY WORN ON
HANDS OR WRI STS TO AVOI D I NJURY BY ACCI -
DENTAL ARCI NG OF BATTERY CURRENT.
WHEN USI NG A HI GH OUTPUT BOOSTI NG
DEVI CE, DO NOT ALLOW THE DI SABLED VEHI -
CLES BATTERY TO EXCEED 16 VOLTS. PER-
SONAL I NJURY OR DAMAGE TO ELECTRI CAL
SYSTEM CAN RESULT.
TO PROTECT THE HANDS FROM BATTERY
ACI D, A SUI TABLE PAI R OF HEAVY DUTY RUB-
Fig. 1 Battery Construction
NS/GS BATTERY 8A - 1
BER GLOVES, NOT THE HOUSEHOLD TYPE,
SHOULD BE WORN WHEN REMOVI NG OR SER-
VI CI NG A BATTERY. SAFETY GLASSES ALSO
SHOULD BE WORN.
A compl etel y normal vehi cl e wi l l have a smal l
amount of current drai n on the battery wi th the key
out of the i gni ti on. I t can range from 5 to 25 mi l l i -
amperes after al l the modul es ti me out. I f a vehi cl e
wi l l not be operated for approxi matel y a 20 days, the
I OD fuse shoul d be pul l ed to el i mi nate the vehi cl e
el ectri cal drai n on the battery. The I OD fuse i s
l ocated i n the Power Di stri buti on Center (PDC).
Refer to the PDC cover for proper fuse.
CHARGING TIME REQUIRED
WARNING: NEVER EXCEED 20 AMPS WHEN
CHARGING A COLD -1C (30F) BATTERY. PER-
SONAL INJURY MAY RESULT.
The ti me requi red to charge a battery wi l l vary
dependi ng upon the fol l owi ng factors.
SIZE OF BATTERY
A compl etel y di scharged l arge heavy-duty battery
may requi re more rechargi ng ti me than a compl etel y
di scharged smal l capaci ty battery, refer to (Fi g. 2) for
chargi ng ti mes.
TEMPERATURE
A l onger ti me wi l l be needed to charge a battery at
-18C (0F) than at 27C (80F). When a fast charger
i s connected to a col d battery, current accepted by
battery wi l l be very l ow at fi rst. I n ti me, the battery
wi l l accept a hi gher rate as battery temperature
warms.
CHARGER CAPACITY
A charger whi ch can suppl y onl y fi ve amperes wi l l
requi re a much l onger peri od of chargi ng than a
charger that can suppl y 20 amperes or more.
STATE OF CHARGE
A compl etel y di scharged battery requi res more
chargi ng ti me than a parti al l y charged battery. El ec-
trol yte i s nearl y pure water i n a compl etel y di s-
charged battery. At fi rst, the chargi ng current
amperage wi l l be l ow. As water i s converted back to
sul furi c aci d i nsi de the battery, the current amp rate
wi l l ri se. Al so, the speci fi c gravi ty of the el ectrol yte
wi l l ri se. The el ectrol yte shoul d be tested wi th a
Hydrometer to check the speci fi c gravi ty.
USING HYDROMETER
Before performi ng a hydrometer test, remove the
battery caps and check the el ectrol yte l evel . Add di s-
ti l l ed water as requi red.
NOTE: Periodically disassemble the hydrometer
and wash components with soap and water. Inspect
the float for possible leaks. If the paper inside has
turned brown, the float is defective.
Before testi ng, vi sual l y i nspect the battery for any
damage:
Cracked contai ner or cover
Loose post
Corrosi on
and any other thi ng that woul d cause the battery
to be unservi ceabl e. To i nterpret the hydrometer cor-
rectl y, hol d i t wi th the top surface of the el ectrol yte
i n the hydrometer at eye l evel .
Di sregard the curvature of the l i qui d where the
surface ri ses agai nst the fl oat because of surface
cohesi on (Fi g. 3). Remove onl y enough el ectrol yte
from the battery to keep the fl oat off the bottom of
the hydrometer barrel wi th pressure on the bul b
rel eased. Keep the hydrometer i n a verti cal posi ti on
whi l e drawi ng the el ectrol yte i nto the hydrometer
and observi ng the speci fi c gravi ty. Exerci se care
when i nserti ng the ti p of the hydrometer i nto a cel l
to avoi d damage to the separators. Damaged separa-
tors can cause premature battery fai l ure.
Hydrometer fl oats are general l y cal i brated to i ndi -
cate the speci fi c gravi ty correctl y onl y at one fi xed
temperature, 20C (68F). When testi ng the speci fi c
gravi ty at any other temperature, a correcti on factor
i s requi red, otherwi se speci fi c gravi ty readi ngs wi l l
not i ndi cate the true state of charge.
The correcti on factor i s approxi matel y a speci fi c
gravi ty val ue of 0.004, referred to as 4 poi nts of spe-
ci fi c gravi ty for every 5.5C (10F). I f el ectrol yte tem-
perature i s bel ow 20C (68F) you subtract. I f the
temperature i s above 20C (68F) you add to the
Fig. 2 Battery Charging Time
8A - 2 BATTERY NS/GS
hydrometer readi ng. Al ways correct the speci fi c grav-
i ty for temperature vari ati on. Test the speci fi c grav-
i ty of the el ectrol yte i n each battery cel l . Refer to the
i nformati on wi th the Hydrometer.
Example 1:
Hydrometer readi ng: 1.260
El ectrol yte temperature: -7C (20F)
Subtract speci fi c gravi ty: -0.019
Correcti on speci fi c gravi ty: 1.241
Example 2:
Hydrometer readi ng: 1.225
El ectrol yte temperature: -38C (100F)
Add speci fi c gravi ty: +0.013
Correcti on speci fi c gravi ty: 1.238
A ful l y charged rel ati vel y new battery has a spe-
ci fi c gravi ty readi ng of 1.285 pl us 0.015 or mi nus
0.010.
I f the speci fi c gravi ty of al l cel l s i s above 1.235, but
vari ati on between cel l s i s more than 50 poi nts
(0.050), i t i s an i ndi cati on that the battery i s unser-
vi ceabl e.
I f the speci fi c gravi ty of one or more cel l s i s l ess
than 1.235, recharge the battery at a rate of approx-
i matel y 5 amperes. Conti nue chargi ng unti l three
consecuti ve speci fi c gravi ty tests, taken at one-hour
i nterval s, are constant.
I f the cel l speci fi c gravi ty vari ati on i s more than 50
poi nts (0.050) at the end of the charge peri od, repl ace
the battery.
When the speci fi c gravi ty of al l cel l s i s above 1.235
and vari ati on between cel l s i s l ess than 50 poi nts
(0.050), the battery may be tested under heavy l oad.
BATTERY DISCHARGING
CAUSE OF BATTERY DISCHARGING
I t i s normal to have a smal l 5 to 25 mi l l i amperes
conti nuous el ectri cal draw from the battery. Thi s
draw wi l l take pl ace wi th the i gni ti on i n the OFF
posi ti on, and the courtesy, dome, storage compart-
ments, and engi ne compartment l i ghts OFF. The con-
ti nuous draw i s due to vari ous el ectroni c features or
accessori es that requi re el ectri cal current wi th the
i gni ti on OFF to functi on properl y. When a vehi cl e i s
not used over an extended peri od of approxi matel y 20
days the I OD fuse shoul d be di sconnected. The fuse
i s l ocated i n the power di stri buti on center. Di sconnec-
ti on of thi s fuse wi l l reduce the l evel of battery di s-
charge. Refer to Battery Di agnosi s and Testi ng Chart
and to the proper procedures.
ABNORMAL BATTERY DISCHARGING
Corroded battery posts, cabl es or termi nal s.
Loose or worn generator dri ve bel t.
El ectri cal l oads that exceed the output of the
chargi ng system due to equi pment or accessori es
i nstal l ed after del i very.
Sl ow dri vi ng speeds i n heavy traffi c condi ti ons
or prol onged i dl i ng wi th hi gh-amperage el ectri cal
systems i n use.
Defecti ve el ectri cal ci rcui t or component causi ng
excess I gni ti on Off Draw (I OD). Refer to Battery
I gni ti on Off Draw (I OD).
Defecti ve chargi ng system.
Defecti ve battery.
BATTERY IGNITION OFF DRAW
Hi gh current draw on the battery wi th the i gni ti on
OFF wi l l di scharge a battery. After a dead battery i s
servi ced the vehi cl e I gni ti on Off Draw (I OD) shoul d
be checked. Determi ne i f a hi gh current draw condi -
ti on exi sts fi rst check the vehi cl e wi th a test l amp.
(1) Veri fy that al l el ectri cal accessori es are OFF.
Remove key from i gni ti on swi tch
Turn off al l l i ghts
Li ftgate and gl ove box door i s cl osed
Sun vi sor vani ty l i ghts are OFF
Al l doors are cl osed
Al l ow the I l l umi nated Entry System to ti me out
i n approxi matel y 30 seconds, i f equi pped.
Fig. 3 Battery Hydrometer
CAUTION: Always disconnect the meter before
opening a door.
(3) Usi ng an mul ti meter, that has l east a mi l l i am-
pere range of 200 mA. Set meter to the hi ghest mA
range. I nstal l meter between the battery negati ve
cabl e and battery negati ve post (Fi g. 5). Careful l y
remove the test l amp wi thout di sconnecti ng the
meter. After al l modul es ti me-out the total vehi cl e
I OD shoul d be l ess than 25 mi l l i amperes. I f i gni ti on
off draw i s more than 25 mi l l i amperes go to Step 4.
(4) Each ti me the test l amp or mi l l i ampere meter
i s di sconnected and connected, al l el ectroni c ti mer
functi ons wi l l be acti vated for approxi matel y one
mi nute. The Body Control Modul e (BCM) i gni ti on off
draw can reach 90 mi l l i amperes.
(5) Remove the PDC fuses:
I nteri or l amps
Brake l amp
I OD
(6) I f there i s any readi ng, wi th fuses removed
there i s a short ci rcui t i n the wi ri ng. Refer to Group
8W, wi ri ng di agrams. I f readi ng i s l ess than 25 mA
go to Step 8.
(7) I nstal l al l fuses. After i nstal l i ng fuse, the cur-
rent can reach 90 mA. After ti me-out the readi ng
shoul d not exceed 25 mA. I f OK go to. I f not, di scon-
nect:
Radi o
BATTERY DIAGNOSIS AND TESTING
STEPS POSSIBLE CAUSE CORRECTION
VISUAL INSPECTION
Check for possible damage to
battery and clean battery.
(1) Corroded post(s) or terminal(s)
(2) Loose terminal(s)
(3) Loose battery post, Cracked
battery cover or case, Leaks or Any
other physical
(4) Battery OK.
(1) Clean post(s) or terminal(s)
(2) Clean and tighten
(3) Replace Battery
(4) Check state of charge. Refer to
Hydrometer Test
PERFORM BATTERY
HYDROMETER TEST
(1) 1.285
(2) 1.235
(3) 1.175 or a variation between
cells of 0.050 or greater
(1) Battery is charged. Perform
Battery 0pen Circuit Voltage Test
procedure.
BATTERY OPEN CIRCUIT
VOLTAGE TEST
(1) Battery is above 12.40 Volts
(2) Battery is below 12.40 Volts.
(1) Perform the Battery Load Test.
procedure.
BATTERY CHARGING (1) Battery accepted Charge.
(2) Battery will not accept charge
(1) Pass Hydrometer Test and
perform Battery 0pen Circuit Voltage
Test
(2) Perform Charging a Completely
Discharged Battery.
BATTERY LOAD TEST (1) Acceptable minimum voltage.
(2) Unacceptable minimum voltage
(1) Battery is OK to put in use,
perform Battery Ignition Off Draw
Test.
(2) Replace Battery and perform
Battery Ignition Off Draw Test.
CHARGING A COMPLETELY
DISCHARGED BATTERY
(1) Battery accepted charge.
(2) Battery will not accept charge.
(1) Pass Hyrometer Test and
perform Battery 0pen Circuit Voltage
Test.
IGNITION OFF DRAW TEST (1) IOD is 5-25 Milliamperes.
(2) IOD Exceeds 25 Milliamperes.
(1) Vehicle is normal.
(2) Eliminate excess IOD draw.
Fig. 4 Disconnect Battery Negative Cable
Remote Keyl ess Entry Modul e
(8) Di sconnect one component at ti me, to see i f any
component i s at faul t. I f the hi gh readi ng i s not el i m-
i nated there i s a short ci rcui t i n the wi ri ng. Refer to
Group 8W, wi ri ng di agrams.
(9) Remove i nteri or and brake l amp fuses. I nstal l
the fuses. The mi l l i ampere readi ng shoul d be 2-4 mA.
I f readi ng i s hi gher than 4 mA:
(a) Di sconnect PCM.
(b) I f readi ng i s OK, repl ace PCM.
(c) I f readi ng does not change there i s a short
ci rcui t to the PCM. Refer to Group 8W, Wi ri ng Di a-
grams.
BATTERY LOAD TEST
A ful l y charged battery must have cranki ng capac-
i ty, to provi de the starter motor and i gni ti on system
enough power to start the engi ne over a broad range
of ambi ent temperatures. A battery l oad test wi l l ver-
i fy the actual cranki ng capabi l i ty of the battery.
WARNING: IF BATTERY SHOWS SIGNS OF FREEZ-
ING, LEAKING, LOOSE POSTS, OR EXCESSIVELY
LOW ELECTROLYTE LEVEL, DO NOT TEST. ACID
BURNS OR AN EXPLOSIVE CONDITION MAY
RESULT.
fi rst. The battery top, cabl es and posts shoul d be
cl ean. Test battery wi th a hydrometer. I f battery
charge i s l ow the charge battery. Refer to Battery
Chargi ng Procedures.
(Fi g. 7).
and then veri fy open ci rcui t vol tage.
(4) Rotate the l oad control knob on the tester to
mai ntai n 50% of the battery col d crank rati ng for 15
seconds (Fi g. 8). Record the l oaded vol tage readi ng
and return the l oad control to off. Refer to the Bat-
tery Speci fi cati ons at the rear of thi s Group.
(5) Vol tage drop wi l l vary accordi ng to battery
temperature at the ti me of the l oad test. Battery
temperature can be esti mated by the temperature of
exposure over the precedi ng several hours. I f the bat-
tery has been charged or boosted a few mi nutes pri or
to the test, the battery woul d be sl i ghtl y warmer.
Refer to Load Test Vol tage Chart for proper l oaded
vol tage readi ng.
Fig. 5 Milliampere Meter Connection
Fig. 6 Volt-Ammeter Load Tester Connections
Fig. 7 Remove Surface Charge From Battery
(6) I f battery passes l oad test, i t i s i n good condi -
ti on and further tests are not necessary. I f i t fai l s
l oad test, i t shoul d be repl aced.
BATTERY OPEN CIRCUIT VOLTAGE TEST
An open ci rcui t vol tage no l oad test shows the
state of charge of a battery and whether i t i s ready
for a l oad test at 50 percent of the batterys col d
crank rati ng. Refer to Battery Load Test. I f a battery
has open ci rcui t vol tage readi ng of 12.4 vol ts or
greater, and wi l l not pass the l oad test, repl ace the
battery because i t i s defecti ve. To test open ci rcui t
vol tage, perform the fol l owi ng operati on.
fi rst. Battery top, cabl es and posts shoul d be cl ean. I f
green dot i s not vi si bl e i n i ndi cator, charge the bat-
tery. Refer to Battery Chargi ng Procedures.
(Fi g. 7).
and then veri fy the open ci rcui t vol tage (Fi g. 9).
(4) Thi s vol tage readi ng wi l l approxi mate the state
of charge of the battery. I t wi l l not reveal battery
cranki ng capaci ty (Fi g. 10).
SERVICE PROCEDURES
BATTERY CHARGING
WARNING: DO NOT CHARGE A BATTERY THAT
HAS EXCESSIVELY LOW ELECTROLYTE LEVEL.
BATTERY MAY SPARK INTERNALLY AND
EXPLODE. EXPLOSIVE GASES FORM OVER THE
BATTERY. DO NOT SMOKE, USE FLAME, OR CRE-
ATE SPARKS NEAR BATTERY. DO NOT ASSIST
BOOST OR CHARGE A FROZEN BATTERY. BAT-
TERY CASING MAY FRACTURE. BATTERY ACID IS
POISON, AND MAY CAUSE SEVERE BURNS. BAT-
TERIES CONTAIN SULFURIC ACID. AVOID CON-
TACT WITH SKIN, EYES, OR CLOTHING. IN THE
EVENT OF CONTACT, FLUSH WITH WATER AND
CALL PHYSICIAN IMMEDIATELY. KEEP OUT OF
REACH OF CHILDREN.
Fig. 8 Load 50% Cold Crank Rating
Load Test Temperature
Minimum Voltage
Temperature
F C
9.6 volts 70and
above
21and
above
9.5 volts 60 16
9.4 volts 50 10
9.3 volts 40 4
9.1 volts 30 -1
8.9 volts 20 -7
8.7 volts 10 -12
8.5 volts 0 -18
Fig. 9 Testing Open Circuit Voltage
Fig. 10 Battery Open Circuit Voltage
CAUTION: Disconnect the battery NEGATIVE cable
first (Fig. 4) before charging battery to avoid dam-
age to electrical systems. Do not exceed 16.0 volts
while charging battery. Refer to the instructions
supplied with charging equipment
A battery i s consi dered ful l y charged when i t wi l l
meet al l the fol l owi ng requi rements.
I t has an open ci rcui t vol tage charge of at l east
12.4 vol ts (Fi g. 10).
I t passes the 15 second l oad test, refer to the
Load Test Temperature chart.
The speci fi c gravi ty readi ng i s 1.285 pl us 0.015
or mi nus 0.010.
Battery el ectrol yte wi l l bubbl e i nsi de of battery
case whi l e bei ng charged properl y. I f the el ectrol yte
boi l s vi ol entl y, or i s di scharged from the vent hol es
whi l e chargi ng, i mmedi atel y reduce chargi ng rate or
turn off charger. Eval uate battery condi ti on. Battery
damage may occur i f chargi ng i s excessi ve.
Some battery chargers are equi pped wi th pol ari ty
sensi ng devi ces to protect the charger or battery from
bei ng damaged i f i mproperl y connected. I f the bat-
tery state of charge i s too l ow for the pol ari ty sensor
to detect, the sensor must be bypassed for charger to
operate. Refer to operati ng i nstructi ons provi ded
wi th battery charger bei ng used.
CAUTION: Do not overcharge Battery.
Test the battery unti l the speci fi c gravi ty readi ng
i s 1.285 pl us 0.015 or mi nus 0.010.
After the battery has been charged to 12.4 vol ts or
greater, perform a l oad test to determi ne cranki ng
capaci ty. Refer to Battery Load Test i n thi s Group. I f
the battery passes the l oad test, return the battery to
use. I f battery wi l l not endure a l oad test, i t must be
repl aced. Properl y cl ean and i nspect battery hol d
downs, tray, termi nal s, cabl es, posts, and top before
compl eti ng servi ce.
CHARGING COMPLETELY DISCHARGED BATTERY
The fol l owi ng procedure shoul d be used to recharge
a compl etel y di scharged battery. Unl ess procedure i s
properl y fol l owed, a good battery may be needl essl y
repl aced (Fi g. 11).
(1) Measure the vol tage at battery posts wi th a
vol tmeter accurate to 1/10 vol t (Fi g. 12). I f bel ow 10
vol ts, charge current wi l l be l ow, and i t coul d take
some ti me before i t accepts a current i n excess of a
few mi l l i amperes. Such l ow current may not be
detectabl e on amp meters bui l t i nto many chargers.
(2) Connect charger l eads. Some chargers feature
pol ari ty protecti on ci rcui try that prevents operati on
unl ess charger i s connected to battery posts correctl y.
A compl etel y di scharged battery may not have
enough vol tage to acti vate thi s ci rcui try. Thi s may
happen even though the l eads are connected properl y.
(3) Battery chargers vary i n the amount of vol tage
and current they provi de. For the ti me requi red for
the battery to accept measurabl e charger current at
vari ous vol tages, refer to (Fi g. 11). I f charge current
i s sti l l not measurabl e after chargi ng ti mes, the bat-
tery shoul d be repl aced. I f charge current i s measur-
abl e duri ng chargi ng ti me, the battery may be good,
and chargi ng shoul d be compl eted i n the normal
manner.
VISUAL INSPECTION
CAUTION: Do not allow baking soda solution to
enter vent holes, as damage to battery can result.
(1) Cl ean top of battery wi th a sol uti on of warm
water and baki ng soda.
(2) Appl y soda sol uti on wi th a bri stl e brush and
al l ow to soak unti l aci d deposi ts l oosen (Fi g. 13).
(3) Ri nse soda sol uti on from battery wi th cl ear
water and bl ot battery dry wi th paper towel i ng. Di s-
pose of towel i ng i n a safe manner. Refer to the
WARNI NGS on top of battery.
(4) I nspect battery case and cover for cracks, l eak-
age or damaged hol d down l edge. I f battery i s dam-
aged repl ace i t.
Fig. 11 Charging Rate
Fig. 12 Voltmeter Accurate to 1/10 Volt (Connected)
(5) I nspect battery tray for damage caused by aci d
from battery. I f aci d i s present, cl ean area wi th bak-
i ng soda sol uti on.
(6) Cl ean battery posts wi th a battery post cl ean-
i ng tool (Fi g. 14).
(7) Cl ean battery cabl e cl amps wi th a battery ter-
mi nal cl eani ng tool (Fi g. 15). Repl ace cabl es that are
frayed or have broken cl amps.
BATTERY
WARNING: TO PROTECT THE HANDS FROM BAT-
TERY ACID, A SUITABLE PAIR OF HEAVY DUTY
RUBBER GLOVES, NOT THE HOUSEHOLD TYPE,
SHOULD BE WORN WHEN REMOVING OR SERVIC-
ING A BATTERY. SAFETY GLASSES ALSO SHOULD
BE WORN.
REMOVAL
(1) Veri fy that the i gni ti on swi tch and al l accesso-
ri es are OFF.
(2) Di sconnect battery cabl e termi nal s from the
battery posts, negati ve fi rst (Fi g. 16).
3
(3) Remove battery hol d down (Fi g. 17).
(4) Remove battery from vehi cl e (Fi g. 18).
INSTALLATION
I nspect and cl ean battery and attachi ng compo-
nents before i nstal l ati on.
(1) I nstal l battery i n vehi cl e maki ng sure that bat-
tery i s properl y posi ti oned on battery tray.
(2) I nstal l battery hol d down.
(3) Connect battery cabl e termi nal s, posi ti ve cabl e
fi rst. Make sure the top of battery termi nal s are
fl ush wi th top of posts.
WARNING: DO NOT OVER TIGHTEN BATTERY
CABLE CLAMPS, DAMAGE TO CLAMPS CAN
RESULT.
Fig. 13 Cleaning Battery
Fig. 14 Cleaning Battery Post
Fig. 15 Cleaning Battery Cable Terminal
(4) Ti ghten termi nal nuts to 8.5 Nm (75 i n. l bs.).
BATTERY TRAY
REMOVAL
(1) Remove battery, refer to the above procedures.
(2) Remove nut and two bol ts from battery tray
(Fi g. 19).
(3) Remove battery tray from vehi cl e.
(4) Remove speed control servo attachi ng bol t from
battery tray (i f equi pped). Use care when di sconnect-
i ng vacuum l i nes from reservoi r (Fi g. 20).
INSTALLATION
SPECIFICATIONS
BATTERY SPECIFICATIONS
CRANKING RATING
The current battery can del i ver for 30 seconds and
mai ntai n a termi nal vol tage of 7.2 vol ts or greater at
speci fi ed temperature.
Fig. 16 Battery Cable Disconnected
Fig. 17 Battery Hold Down
Fig. 18 Remove Battery
Fig. 19 Battery Tray Removal
TORQUE
DESCRIPTION TORQUE
Battery Hol d Down Bol t Cl amp
Bol t . . . . . . . . . . . . . . . . . . . 14 Nm (125 i n. l bs.)
Fig. 20 Speed Control Servo Removal
Reserve Cold Cranking Reserve
(Amps) Rating @ -17.8C (0.0F) Capacity
DIN/BCI
200 Amp 500 Amp 110
Minutes
250 Amp 600 Amp 120
Minutes
315 Amp 685 Amp 125
Minutes
STARTER
CONTENTS
page page
GENERAL INFORMATION
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . 1
SUPPLY CIRCUIT AND CONTROL CIRCUIT . . . . 1
CONTROL CIRCUIT TEST . . . . . . . . . . . . . . . . . . 1
FEED CIRCUIT RESISTANCE TEST . . . . . . . . . . . 3
FEED CIRCUIT TEST . . . . . . . . . . . . . . . . . . . . . . 4
STARTER2.4L ENGINE . . . . . . . . . . . . . . . . . . 5
STARTER3.0L ENGINE . . . . . . . . . . . . . . . . . . 6
STARTER3.3/3.8L ENGINE . . . . . . . . . . . . . . . 6
SPECIFICATIONS
STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
GENERAL INFORMATION
INTRODUCTION
The starti ng system has (Fi g. 1):
I gni ti on swi tch
Starter rel ay
Powertrai n Control Modul e (PCM) doubl e start
overri de
Neutral starti ng and back up swi tch wi th auto-
mati c transmi ssi ons onl y
Wi ri ng harness
Battery
Starter motor wi th an i ntegral sol enoi d
Posi ti ve Temperature Coeffi ci ent (PTC) i s the
ci rcui t protecti on for the i gni ti on feed to the starter
rel ay coi l . The PTC i s l ocated i n the Juncti on Bl ock.
These components form two separate ci rcui ts. A
hi gh amperage ci rcui t that feeds the starter motor up
to 300+ amps, and a control ci rcui t that operates on
l ess than 20 amps.
SUPPLY CIRCUIT AND CONTROL CIRCUIT
The starter system consi sts of two separate ci r-
cui ts:
A hi gh amperage suppl y to feed the starter
motor.
A l ow amperage ci rcui t to control the starter
sol enoi d.
CONTROL CIRCUIT TEST
The starter control ci rcui t has:
Starter sol enoi d
Starter rel ay
Fig. 1 Starting System Components
NS STARTER 8B - 1
Transmi ssi on range sensor, or Park/Neutral
Posi ti on swi tch wi th automati c transmi ssi ons
Cl utch Pedal Posi ti on Swi tch wi th manual
transmi ssi ons
I gni ti on swi tch
Battery
Al l rel ated wi ri ng and connecti ons
CAUTION: Before performing any starter tests, the
ignition and fuel systems must be disabled.
To di sabl e i gni ti on and fuel systems, di sconnect
the Automati c Shutdown Rel ay (ASD). The ASD rel ay
i s l ocated i n the i n the Power Di stri buti on Center
(PDC). Refer to the PDC cover for the proper rel ay
l ocati on.
STARTER SOLENOID
WARNING: CHECK TO ENSURE THAT THE TRANS-
MISSION IS IN THE PARK POSITION WITH THE
PARKING BRAKE APPLIED
(1) Veri fy battery condi ti on. Battery must be i n
good condi ti on wi th a ful l charge before performi ng
any starter tests. Refer to Battery Tests.
(2) Perform Starter Sol enoi d test BEFORE per-
formi ng the starter rel ay test.
(4) Perform a vi sual i nspecti on of the starter/
starter sol enoi d for corrosi on, l oose connecti ons or
faul ty wi ri ng.
(6) Locate and remove the starter rel ay from the
Power Di stri buti on Center (PDC). Refer to the PDC
l abel for rel ay i denti fi cati on and l ocati on.
(7) Connect a remote starter swi tch or a jumper
wi re between the remote battery posi ti ve post and
termi nal 87 of the starter rel ay connector.
(a) I f engi ne cranks, starter/starter sol enoi d i s
good. Go to the Starter Rel ay Test.
(b) I f engi ne does not or sol enoi d chatters, check
wi ri ng and connectors from starter rel ay to starter
sol enoi d for l oose or corroded connecti ons. Parti cu-
l arl y at starter termi nal s.
(c) Repeat test. I f engi ne sti l l fai l s to crank prop-
erl y, troubl e i s wi thi n starter or starter mounted
sol enoi d, and repl ace starter.
STARTER RELAY
WARNING: CHECK TO ENSURE THAT THE TRANS-
MISSION IS IN THE PARK POSITION/NEUTRAL
WITH THE PARKING BRAKE APPLIED
RELAY TEST
The starter rel ay i s l ocated i n the Power Di stri bu-
ti on Center (PDC) i n the engi ne compartment. Refer
to the PDC l abel for rel ay i denti fi cati on and l ocati on.
Remove the starter rel ay from the PDC as
descri bed i n thi s group to perform the fol l owi ng tests:
(1) A rel ay i n the de-energi zed posi ti on shoul d
have conti nui ty between termi nal s 87A and 30, and
no conti nui ty between termi nal s 87 and 30. I f OK, go
to Step 2. I f not OK, repl ace the faul ty rel ay.
(2) Resi stance between termi nal s 85 and 86 (el ec-
tromagnet) shoul d be 75 5 ohms. I f OK, go to Step
3. I f not OK, repl ace the faul ty rel ay.
(3) Connect a battery B+ l ead to termi nal s 86 and
a ground l ead to termi nal 85 to energi ze the rel ay.
The rel ay shoul d cl i ck. Al so test for conti nui ty
between termi nal s 30 and 87, and no conti nui ty
between termi nal s 87A and 30. I f OK, refer to Rel ay
Ci rcui t Test procedure. I f not OK, repl ace the faul ty
rel ay.
RELAY CIRCUIT TEST
(1) The rel ay common feed termi nal cavi ty (30) i s
connected to battery vol tage and shoul d be hot at al l
ti mes. I f OK, go to Step 2. I f not OK, repai r the open
ci rcui t to the PDC fuse as requi red.
(2) The rel ay normal l y cl osed termi nal (87A) i s
connected to termi nal 30 i n the de-energi zed posi ti on,
but i s not used for thi s appl i cati on. Go to Step 3.
(3) The rel ay normal l y open termi nal (87) i s con-
nected to the common feed termi nal (30) i n the ener-
gi zed posi ti on. Thi s termi nal suppl i es battery vol tage
to the starter sol enoi d fi el d coi l s. There shoul d be
conti nui ty between the cavi ty for rel ay termi nal 87
and the starter sol enoi d termi nal at al l ti mes. I f OK,
go to Step 4. I f not OK, repai r the open ci rcui t to the
starter sol enoi d as requi red.
(4) The coi l battery termi nal (86) i s connected to
the el ectromagnet i n the rel ay. I t i s energi zed when
the i gni ti on swi tch i s hel d i n the Start posi ti on. On
Starter Relay
8B - 2 STARTER NS
vehi cl es wi th a manual transmi ssi on, the cl utch
pedal must be ful l y depressed for thi s test. Check for
battery vol tage at the cavi ty for rel ay termi nal 86
wi th the i gni ti on swi tch i n the Start posi ti on, and no
vol tage when the i gni ti on swi tch i s rel eased to the
On posi ti on. I f OK, go to Step 5. I f not OK wi th an
automati c transmi ssi on, check for an open or short
ci rcui t to the i gni ti on swi tch and repai r, i f requi red.
I f the ci rcui t to the i gni ti on swi tch i s OK, see the
I gni ti on Swi tch Test procedure i n thi s group. I f not
OK wi th a manual transmi ssi on, check the ci rcui t
between the rel ay and the cl utch pedal posi ti on
swi tch for an open or a short. I f the ci rcui t i s OK, see
the Cl utch Pedal Posi ti on Swi tch Test procedure i n
thi s group.
(5) The coi l ground termi nal (85) i s connected to
the el ectromagnet i n the rel ay. On vehi cl es wi th an
automati c transmi ssi on, i t i s grounded through the
park/neutral posi ti on swi tch onl y when the gearshi ft
sel ector l ever i s i n the Park or Neutral posi ti ons. On
vehi cl es wi th a manual transmi ssi on, i t i s grounded
at al l ti mes. Check for conti nui ty to ground at the
cavi ty for rel ay termi nal 85. I f not OK wi th an auto-
mati c transmi ssi on, check for an open or short ci rcui t
to the park/neutral posi ti on swi tch and repai r, i f
requi red. I f the ci rcui t i s OK, see the Park/Neutral
Posi ti on Swi tch Test procedure i n thi s group. I f not
OK wi th a manual transmi ssi on, repai r the ci rcui t to
ground as requi red.
SAFETY SWITCHES
For di agnosti cs,
Cl utch Pedal Posi ti on Swi tch, refer to Group 6,
Cl utch.
Park/Neutral Posi ti on Swi tch, refer to Group 21,
Transaxl e
IGNITION SWITCH
After testi ng starter sol enoi d and rel ay, test i gni -
ti on swi tch and wi ri ng. Refer to Group 8D, I gni ti on
Systems or Group 8W, Wi ri ng Di agrams. Check al l
wi ri ng for opens or shorts, and al l connectors for
bei ng l oose or corroded.
BATTERY
Refer to Group 8A, Battery for proper procedures.
ALL RELATED WIRING AND CONNECTORS
Refer to Group 8W, Wi ri ng Di agrams,
FEED CIRCUIT RESISTANCE TEST
Before proceedi ng wi th thi s operati on, revi ew Di ag-
nosti c Preparati on and Starter Feed Ci rcui t Tests.
The fol l owi ng operati on wi l l requi re a vol tmeter,
accurate to 1/10 of a vol t.
(1) To di sabl e the i gni ti on and fuel systems, di s-
connect the Automati c Shutdown Rel ay (ASD). The
ASD rel ay i s l ocated i n the Power Di stri buti on Cen-
ter (PDC). Refer to the PDC cover for proper rel ay
l ocati on.
(2) Wi th al l wi ri ng harnesses and components
properl y connected, perform the fol l owi ng:
(a) Connect the negati ve l ead of the vol tmeter to
the battery negati ve post, and posi ti ve l ead to the
battery negati ve cabl e cl amp (Fi g. 2). Rotate and
hol d the i gni ti on swi tch i n the START posi ti on.
Observe the vol tmeter. I f vol tage i s detected, cor-
rect poor contact between cabl e cl amp and post.
(b) Connect posi ti ve l ead of the vol tmeter to the
battery posi ti ve post, and negati ve l ead to the bat-
tery posi ti ve cabl e cl amp. Rotate and hol d the i gni -
ti on swi tch key i n the START posi ti on. Observe the
vol tmeter. I f vol tage i s detected, correct poor con-
tact between the cabl e cl amp and post.
(c) Connect negati ve l ead of vol tmeter to battery
negati ve termi nal , and posi ti ve l ead to engi ne
Fig. 2 Test Battery Connection Resistance
NS STARTER 8B - 3
bl ock near the battery cabl e attachi ng poi nt (Fi g.
3). Rotate and hol d the i gni ti on swi tch i n the
START posi ti on. I f vol tage reads above 0.2 vol t,
correct poor contact at ground cabl e attachi ng
poi nt. I f vol tage readi ng i s sti l l above 0.2 vol t after
correcti ng poor contacts, repl ace ground cabl e.
(3) Connect posi ti ve vol tmeter l ead to the starter
motor housi ng and the negati ve l ead to the battery
negati ve termi nal (Fi g. 4). Hol d the i gni ti on swi tch
key i n the START posi ti on. I f vol tage reads above 0.2
vol t, correct poor starter to engi ne ground.
(a) Connect the posi ti ve vol tmeter l ead to the
battery posi ti ve termi nal , and negati ve l ead to bat-
tery cabl e termi nal on starter sol enoi d (Fi g. 5).
Rotate and hol d the i gni ti on swi tch i n the START
posi ti on. I f vol tage reads above 0.2 vol t, correct
poor contact at battery cabl e to sol enoi d connec-
ti on. I f readi ng i s sti l l above 0.2 vol t after correct-
i ng poor contacts, repl ace battery posi ti ve cabl e.
(b) I f resi stance tests do not detect feed ci rcui t
fai l ures, remove the starter motor and go to
Starter Sol enoi d Test i n thi s Group.
FEED CIRCUIT TEST
The fol l owi ng procedure wi l l requi re a sui tabl e
vol t-ampere tester (Fi g. 6).
Fig. 4 Test Starter Motor Ground
Fig. 3 Test Ground Circuit Resistance
Fig. 5 Test Battery Positive Cable Resistance
Fig. 6 Volt Ampere Tester
8B - 4 STARTER NS
(1) Connect a vol t-ampere tester to the battery ter-
mi nal s (Fi g. 7). Refer to the operati ng i nstructi ons
provi ded wi th the tester bei ng used.
(2) To di sabl e the i gni ti on and fuel systems, di s-
connect the Automati c Shutdown Rel ay (ASD). The
ASD rel ay i s l ocated i n the Power Di stri buti on Cen-
ter (PDC). Refer to the PDC cover for proper rel ay
l ocati on. The 2.5L Di esel Engi ne, to di sabl e the
engi ne from starti ng, di sconnect wi re connector from
the Fuel Sol enoi d.
(3) Veri fy that al l l i ghts and accessori es are OFF,
and the transmi ssi on shi ft sel ector i s i n the PARK
posi ti on or wi th the cl utch pedal depressed and SET
parki ng brake.
CAUTION: Do not overheat the starter motor or
draw the battery voltage below 9.6 volts during
cranking operations.
(4) Rotate and hol d the i gni ti on swi tch i n the
START posi ti on. Observe the vol t-ampere tester (Fi g.
6).
I f vol tage reads above 9.6 vol ts, and amperage
draw reads above 280 amps or the Di esel engi ne
above 450 amps, check for engi ne sei zi ng or faul ty
starter.
I f vol tage reads 12.4 vol ts or greater and amper-
age reads 0 to 10 amps, check for corroded cabl es
and/or bad connecti ons.
Vol tage bel ow 9.6 vol ts and amperage draw
above 300 amps or Di esel engi ne above 500 amps,
the probl em i s the starter. Repl ace the starter refer
to starter removal .
(5) After the starti ng system probl ems have been
corrected, veri fy the battery state-of-charge and
charge battery i f necessary. Di sconnect al l testi ng
equi pment and connect ASD rel ay or the Fuel Sol e-
noi d. Start the vehi cl e several ti mes to assure the
probl em has been corrected.
STARTER2. 4L ENGINE
REMOVAL
(1) Rel ease hood l atch and open hood.
(3) Hoi st and support vehi cl e on safety stands.
(4) Di sconnect sol enoi d wi re connector from termi -
nal .
(5) Remove nut hol di ng B+ wi re to termi nal .
(6) Di sconnect sol enoi d and B+ wi res from starter
termi nal s.
(7) Remove bol ts hol di ng starter to transaxl e bel l -
housi ng (Fi g. 9).
(8) Remove starter.
Fig. 7 Volt-Ampere Tester Connections
Fig. 8 Battery Negative Cable
Fig. 9 Starter2.4L Engine
NS STARTER 8B - 5
INSTALLATION
(1) Pl ace starter i n posi ti on on vehi cl e.
(2) I nstal l bol ts to hol d starter to transaxl e bel l -
housi ng.
(3) Pl ace sol enoi d and B+ wi res i n posi ti on on
starter termi nal s.
(4) I nstal l nut to hol d B+ wi re to termi nal .
(5) Connect sol enoi d wi re connector onto termi nal .
(7) Connect battery negati ve cabl e.
(8) Veri fy starter operati on.
STARTER3. 0L ENGINE
REMOVAL
(4) Remove nut hol di ng sol enoi d wi re to termi nal
(Fi g. 10).
(5) Remove nut hol di ng B+ wi re to termi nal (Fi g.
6)
termi nal s.
housi ng (Fi g. 11).
(8) Remove starter.
INSTALLATION
housi ng.
(5) I nstal l nut to hol d sol enoi d wi re to termi nal .
STARTER3. 3/3. 8L ENGINE
REMOVAL
(4) Remove nut hol di ng B+ termi nal to starter
sol enoi d (Fi g. 12).
(5) Di sconnect sol enoi d connector from starter.
(7) Remove starter from bel l housi ng (Fi g. 14).
(8) Separate starter spacer from transaxl e bel l -
housi ng.
INSTALLATION
(1) Pl ace starter spacer i n posi ti on on transaxl e
bel l housi ng, fl ange toward fl ywheel .
(2) Pl ace starter i n posi ti on on bel l housi ng.
housi ng.
Fig. 10 Wire Connectors
8B - 6 STARTER NS
(4) Connect sol enoi d connector i nto starter.
(5) I nstal l nut to hol d B+ termi nal to starter sol e-
noi d.
SPECIFICATIONS
STARTER
Engi ne shoul d be up to operati ng temperature.
Extremel y heavy oi l or ti ght engi ne wi l l i ncrease
starter amperage draw.
TORQUE
DESCRIPTION TORQUE
Starter Mounti ng Bol ts . . . . . . . . .54 Nm (40 ft. l bs.)
Starter Sol enoi d Battery Nut . . . .10 Nm (90 i n. l bs.)
Fig. 13 Starter Bolts
Fig. 14 Starter3.3/3.8L Engine
MANUFACTURER NIPPONDENSO
Engine Application 2.4L /3.0L /3.3/3.8L
Power rating 1.2 Kw
Voltage 12 VOLTS
No. of Fields 4
No. of Poles 4
Brushes 4
Drive Conventional Gear Train
Free running Test
Voltage 11
Amperage Draw 73 Amp
Minimum Speed 3401 RPM
SolenoidClosing Voltage 7.5 Volts
Cranking Amperage Draw
test
150 - 200 Amps.
NS STARTER 8B - 7
STARTING SYSTEM
CONTENTS
page
STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
STARTER
2.0L ENGINE
REMOVAL
nal .
termi nal s.
housi ng (Fi g. 2).
(7) Remove starter.
INSTALLATION
(2) I nstal l starter attachi ng bol ts to transaxl e bel l -
housi ng and ti ghten to the proper torque.
Fig. 1 Battery Negative Cable
Fig. 2 Starter - 2.0L Engine
NS/GS STARTING SYSTEM 8B - 1
2.4L ENGINE - With Manual Transaxle
REMOVAL
nal .
termi nal s.
housi ng (Fi g. 3).
(8) Remove starter.
INSTALLATION
2.4L ENGINE - With Automatic Transaxle
REMOVAL
nal .
termi nal s.
Fig. 3 Starter - 2.4L Engine with Manual Transaxle
8B - 2 STARTING SYSTEM NS/GS
housi ng (Fi g. 4).
(8) Remove starter.
INSTALLATION
housi ng and ti ghten to the proper torque
3.0L ENGINE
REMOVAL
(4) Remove nut hol di ng sol enoi d wi re to termi nal
(Fi g. 5).
(5) Remove nut hol di ng B+ wi re to termi nal (Fi g.
6)
termi nal s.
Fig. 4 Starter - 2.4L Engine with Automatic Transaxle
housi ng (Fi g. 6).
(8) Remove starter.
INSTALLATION
(5) I nstal l nut to hol d sol enoi d wi re to termi nal .
3.3/3.8L ENGINE
REMOVAL
(4) Remove nut hol di ng B+ termi nal to starter
sol enoi d (Fi g. 7).
(5) Di sconnect sol enoi d connector from starter.
housi ng.
(7) Remove starter from bel l housi ng (Fi g. 8).
(8) Separate starter spacer from transaxl e bel l -
housi ng.
INSTALLATION
(1) Pl ace starter spacer i n posi ti on on transaxl e
bel l housi ng, fl ange toward fl ywheel .
(2) Pl ace starter i n posi ti on on bel l housi ng.
(4) Connect sol enoi d connector i nto starter.
(5) I nstal l nut to hol d B+ termi nal to starter sol e-
noi d.
8B - 4 STARTING SYSTEM NS/GS
2.5L DIESEL ENGINE
REMOVAL
nal .
termi nal .
(7) Remove three bol ts hol di ng starter to transaxl e
bel l housi ng (Fi g. 9).
(8) Remove starter.
INSTALLATION
For i nstal l ati on, reverse the above procedures and
veri fy the operati on of the starter.
Fig. 8 Starter3.3/3.8L Engine
Fig. 9 Starter2.5L Diesel Engine
CHARGING SYSTEM
CONTENTS
page page
GENERAL INFORMATION
OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
BATTERY TEMPERATURE SENSOR . . . . . . . . . . 2
CHARGING SYSTEM OPERATION . . . . . . . . . . . 1
ELECTRONIC VOLTAGE REGULATOR . . . . . . . . . 2
GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
CHARGING SYSTEM RESISTANCE TESTS . . . . . 4
CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . 2
CURRENT OUTPUT TEST . . . . . . . . . . . . . . . . . . 4
ON-BOARD DIAGNOSTIC SYSTEM TEST . . . . . . 7
GENERATOR2.4L ENGINE . . . . . . . . . . . . . . . . 9
GENERATOR3.0L ENGINE . . . . . . . . . . . . . . . . 9
GENERATOR3.3/3.8 L ENGINE . . . . . . . . . . . 10
SPECIFICATIONS
GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
GENERAL INFORMATION
OVERVIEW
The battery, starti ng, and chargi ng systems oper-
ate wi th one another, and must be tested as a com-
pl ete system. I n order for the vehi cl e to start and
charge properl y, al l of the components i nvol ved i n
these systems must perform wi thi n speci fi cati ons.
Group 8A covers the battery, Group 8B covers the
starti ng system, and Group 8C covers the chargi ng
system. Refer to Group 8W - Wi ri ng Di agrams for
compl ete ci rcui t descri pti ons and di agrams. We have
separated these systems to make i t easi er to l ocate
the i nformati on you are seeki ng wi thi n thi s Servi ce
Manual . However, when attempti ng to di agnose any
of these systems, i t i s i mportant that you keep thei r
i nterdependency i n mi nd.
The di agnosti c procedures used i n these groups
i ncl ude the most basi c conventi onal di agnosti c meth-
ods to the more sophi sti cated On-Board Di agnosti cs
(OBD) bui l t i nto the Powertrai n Control Modul e
(PCM). Use of an i nducti on ammeter, vol t/ohmmeter,
battery charger, carbon pi l e rheostat (l oad tester),
and 12-vol t test l amp may be requi red.
Al l OBD-sensed systems are moni tored by the
PCM. Each moni tored ci rcui t i s assi gned a Di agnos-
ti c Troubl e Code (DTC). The PCM wi l l store a DTC i n
el ectroni c memory for any fai l ure i t detects. See the
On-Board Di agnosti cs Test i n Group 8C - Chargi ng
System for more i nformati on.
CHARGING SYSTEM OPERATION
The chargi ng system consi sts of:
Generator
El ectroni c Vol tage Regul ator (EVR) ci rcui try
wi thi n the Powertrai n Control Modul e (PCM)
I gni ti on swi tch (refer to Group 8D, I gni ti on Sys-
tem for i nformati on)
Battery (refer to Group 8A, Battery for i nforma-
ti on)
Temperature i s measured by a sensor i n the
PCM ci rcui try
Wi ri ng harness and connecti ons (refer to Group
8W, Wi ri ng for i nformati on)
The chargi ng system i s turned on and off wi th the
i gni ti on swi tch. When the i gni ti on swi tch i s turned to
the ON posi ti on, battery vol tage i s appl i ed to the
generator rotor through one of the two fi el d termi -
nal s to produce a magneti c fi el d. The generator i s
dri ven by the engi ne through a serpenti ne bel t and
pul l ey arrangement.
The amount of DC current produced by the gener-
ator i s control l ed by the EVR (fi el d control ) ci rcui try,
contai ned wi thi n the PCM. Thi s ci rcui try i s con-
nected i n seri es wi th the second rotor fi el d termi nal
and ground.
Al l vehi cl es are equi pped wi th On-Board Di agnos-
ti cs (OBD). Al l OBD-sensed systems, i ncl udi ng the
EVR (fi el d control ) ci rcui try, are moni tored by the
PCM. Each moni tored ci rcui t i s assi gned a Di agnos-
ti c Troubl e Code (DTC). The PCM wi l l store a DTC i n
el ectroni c memory for any fai l ure i t detects. See On-
Board Di agnosti c System Test i n thi s group for more
i nformati on.
NS CHARGING SYSTEM 8C - 1
GENERATOR
The generator i s bel t-dri ven by the engi ne. I t i s
servi ced onl y as a compl ete assembl y. I f the genera-
tor fai l s for any reason, the enti re assembl y must be
repl aced.
As the energi zed rotor begi ns to rotate wi thi n the
generator, the spi nni ng magneti c fi el d i nduces a cur-
rent i nto the wi ndi ngs of the stator coi l . Once the
generator begi ns produci ng suffi ci ent current, i t al so
provi des the current needed to energi ze the rotor.
The Y type stator wi ndi ng connecti ons del i ver the
i nduced AC current to 3 posi ti ve and 3 negati ve
di odes for recti fi cati on. From the di odes, recti fi ed DC
current i s del i vered to the vehi cl e el ectri cal system
through the generator, battery, and ground termi nal s.
Noi se emi tti ng from the generator may be caused
by:
Worn, l oose or defecti ve beari ngs
Loose or defecti ve dri ve pul l ey
I ncorrect, worn, damaged or mi sadjusted dri ve
bel t
Loose mounti ng bol ts
Mi sal i gned dri ve pul l ey
Defecti ve stator or di ode
BATTERY TEMPERATURE SENSOR
The temperature sensor, i n the PCM, i s used to
determi ne the battery temperature. Thi s temperature
data, al ong wi th data from moni tored l i ne vol tage, i s
used by the PCM to vary the battery chargi ng rate.
System vol tage wi l l be hi gher at col der temperatures
and i s gradual l y reduced at warmer temperatures.
ELECTRONIC VOLTAGE REGULATOR
The El ectroni c Vol tage Regul ator (EVR) i s not a
separate component. I t i s actual l y a vol tage regul at-
i ng ci rcui t l ocated wi thi n the Powertrai n Control
Modul e (PCM). The EVR i s not servi ced separatel y. I f
repl acement i s necessary, the PCM must be repl aced.
Operation: The amount of DC current produced
by the generator i s control l ed by EVR ci rcui try con-
tai ned wi thi n the PCM. Thi s ci rcui try i s connected i n
seri es wi th the generators second rotor fi el d termi nal
and i ts ground.
Vol tage i s regul ated by cycl i ng the ground path to
control the strength of the rotor magneti c fi el d. The
EVR ci rcui try moni tors system l i ne vol tage and bat-
tery temperature (refer to Battery Temperature Sen-
sor for more i nformati on). I t then compensates and
regul ates generator current output accordi ngl y. Al so
refer to Chargi ng System Operati on for addi ti onal
i nformati on.
CHARGING SYSTEM
When the i gni ti on swi tch i s turned to the ON posi -
ti on, battery potenti al wi l l regi ster on the vol tmeter.
Duri ng engi ne cranki ng a l ower vol tage wi l l appear
on the meter. Wi th the engi ne runni ng, a vol tage
readi ng hi gher than the fi rst readi ng (i gni ti on i n ON)
shoul d regi ster.
The fol l owi ng are possi bl e symptoms of a chargi ng
system faul t:
The vol tmeter does not operate properl y
An undercharged or overcharged battery condi -
ti on occurs.
Remember that an undercharged battery i s often
caused by:
Accessori es bei ng l eft on wi th the engi ne not
runni ng
A faul ty or i mproperl y adjusted swi tch that
al l ows a l amp to stay on. See I gni ti on-Off Draw Test
i n Group 8A, Battery for more i nformati on.
The fol l owi ng procedures may be used to correct a
probl em di agnosed as a chargi ng system faul t.
INSPECTION
(1) I nspect condi ti on of battery cabl e termi nal s,
battery posts, connecti ons at engi ne bl ock, starter
sol enoi d and rel ay. They shoul d be cl ean and ti ght.
Repai r as requi red.
(2) I nspect al l fuses i n the fusebl ock modul e and
Power Di stri buti on Center (PDC) for ti ghtness i n
receptacl es. They shoul d be properl y i nstal l ed and
ti ght. Repai r or repl ace as requi red.
(3) I nspect the el ectrol yte l evel i n the battery.
Repl ace battery i f el ectrol yte l evel i s l ow.
(4) I nspect generator mounti ng bol ts for ti ghtness.
Repl ace or ti ghten bol ts i f requi red. Refer to the Gen-
erator Removal /I nstal l ati on secti on of thi s group for
torque speci fi cati ons.
(5) I nspect generator dri ve bel t condi ti on and ten-
si on. Ti ghten or repl ace bel t as requi red. Refer to
Bel t Tensi on Speci fi cati ons i n Group 7, Cool i ng Sys-
tem.
(6) I nspect automati c bel t tensi oner (i f equi pped).
Refer to Group 7, Cool i ng System for i nformati on.
(7) I nspect connecti ons at generator fi el d, battery
output, and ground termi nal s. Al so check ground con-
necti on at engi ne. They shoul d al l be cl ean and ti ght.
Repai r as requi red.
8C - 2 CHARGING SYSTEM NS
C
H
A
R
G
I
N
G
S
Y
S
T
E
M
S
C
H
E
M
A
T
I
C
T
Y
P
I
C
A
L
CHARGING SYSTEM RESISTANCE TESTS
These tests wi l l show the amount of vol tage drop
across the generator output wi re from the generator
output (B+) termi nal to the battery posi ti ve post.
They wi l l al so show the amount of vol tage drop from
the ground (-) termi nal on the generator or case
ground (Fi g. 1) to the battery negati ve post.
A vol tmeter wi th a 018 vol t DC scal e shoul d be
used for these tests. By reposi ti oni ng the vol tmeter
test l eads, the poi nt of hi gh resi stance (vol tage drop)
can easi l y be found.
PREPARATION
(1) Before starti ng test, make sure battery i s i n
good condi ti on and i s ful l y-charged. See Group 8A,
Battery for more i nformati on.
(2) Check condi ti on of battery cabl es at battery.
Cl ean i f necessary.
(3) Start the engi ne and al l ow i t to reach normal
operati ng temperature.
(4) Shut engi ne off.
(5) Connect an engi ne tachometer.
(6) Ful l y engage the parki ng brake.
TEST
(1) Start engi ne.
(2) Pl ace heater bl ower i n hi gh posi ti on.
(3) Turn on headl amps and pl ace i n hi gh-beam
posi ti on.
(4) Turn rear wi ndow defogger on.
(5) Bri ng engi ne speed up to 2400 rpm and hol d.
(6) Testi ng (+ posi ti ve) ci rcui try:
(a) Touch the negati ve l ead of vol tmeter di rectl y
to battery posi ti ve POST (Fi g. 2).
(b) Touch the posi ti ve l ead of vol tmeter to the
B+ output termi nal stud on the generator (not the
termi nal mounti ng nut). Vol tage shoul d be no
hi gher than 0.6 vol ts. I f vol tage i s hi gher than 0.6
vol ts, touch test l ead to termi nal mounti ng stud
nut and then to the wi ri ng connector. I f vol tage i s
now bel ow 0.6 vol ts, l ook for di rty, l oose or poor
connecti on at thi s poi nt. Al so check condi ti on of the
generator output wi re-to-battery bul l et connector.
Refer to Group 8, Wi ri ng for connector l ocati on. A
vol tage drop test may be performed at each (-
ground) connecti on i n thi s ci rcui t to l ocate the
excessi ve resi stance.
(7) Testi ng (- ground) ci rcui try:
(a) Touch the posi ti ve l ead of vol tmeter di rectl y
to battery negati ve POST.
(b) Touch the negati ve l ead of vol tmeter to the
generator case. Vol tage shoul d be no hi gher than
0.3 vol ts. I f vol tage i s hi gher than 0.3 vol ts, touch
test l ead to generator case and then to the engi ne
bl ock. I f vol tage i s now bel ow 0.3 vol ts, l ook for
di rty, l oose or poor connecti on at thi s poi nt. A vol t-
age drop test may be performed at each connecti on
i n thi s ci rcui t to l ocate the excessi ve resi stance.
Thi s test can al so be performed between the gener-
ator case and the engi ne. I f test vol tage i s hi gher
than 0.3 vol ts, check for corrosi on at generator
mounti ng poi nts or l oose generator mounti ng.
CURRENT OUTPUT TEST
The current output test wi l l determi ne i f the
chargi ng system can del i ver i ts mi ni mum test cur-
rent (amperage) output. Refer to the Speci fi cati ons
secti on at the end of thi s group for mi ni mum test
current (amperage) requi rements.
The fi rst part of thi s test wi l l determi ne the com-
bi ned amperage output of both the generator and the
El ectroni c Vol tage Regul ator (EVR) ci rcui try.
PREPARATION
(1) Determi ne i f any Di agnosti c Troubl e Codes
(DTC) exi st. To determi ne a DTC, refer to On-Board
Di agnosti cs i n thi s group. For repai r, refer to the
appropri ate Powertrai n Di agnosti c Procedures man-
ual .
(2) Before starti ng test, make sure battery i s i n
good condi ti on and i s ful l y-charged. See Group 8A,
Battery for more i nformati on.
(3) Check condi ti on of battery cabl es at battery.
Cl ean i f necessary.
(4) Perform the Vol tage Drop Test. Thi s wi l l
ensure cl ean and ti ght generator/battery el ectri cal
connecti ons.
(5) Be sure the generator dri ve bel t i s properl y
tensi oned. Refer to Group 7, Cool i ng System for
i nformati on.
(6) A vol t/amp tester equi pped wi th both a battery
l oad control (carbon pi l e rheostat) and an i nducti ve-
type pi ckup cl amp (ammeter probe) wi l l be used for
thi s test. Refer to operati ng i nstructi ons suppl i ed
wi th tester. When usi ng a tester equi pped wi th an
i nducti ve-type cl amp, removal of wi ri ng at the gener-
ator wi l l not be necessary.
(7) Start the engi ne and al l ow i t to reach operati ng
temperature.
(8) Shut engi ne off.
(9) Turn off al l el ectri cal accessori es and al l vehi cl e
l i ghti ng.
(10) Connect the vol t/amp tester l eads to the bat-
tery. Be sure the carbon pi l e rheostat control i s i n the
OPEN or OFF posi ti on before connecti ng l eads. See
Load Test i n Group 8A, Battery for more i nformati on.
Al so refer to the operati ng i nstructi ons suppl i ed wi th
test equi pment.
(11) Connect the i nducti ve cl amp (ammeter probe).
Refer to the operati ng i nstructi ons suppl i ed wi th test
equi pment.
(12) I f vol t/amp tester i s not equi pped wi th an
engi ne tachometer, connect a separate tachometer to
the engi ne.
CHARGING SYSTEM TEST
OVERCHARGE TEST
TEST
(1) Perform the previ ous test Preparati on.
(2) Ful l y engage the parki ng brake.
(3) Start engi ne.
(4) Bri ng engi ne speed to 2500 rpm.
(5) Wi th engi ne speed hel d at 2500 rpm, sl owl y
adjust the rheostat control (l oad) on the tester to
obtai n the hi ghest amperage readi ng. Do not al l ow
vol tage to drop bel ow 12 vol ts. Record the readi ng.
This load test must be performed within 15 sec-
onds to prevent damage to test equipment. On
certai n brands of test equi pment, thi s l oad wi l l be
appl i ed automati cal l y. Refer to the operati ng manual
suppl i ed wi th test equi pment.
(6) The ammeter readi ng must meet the Mi ni mum
Test Amps speci fi cati ons as di spl ayed i n the Genera-
tor Rati ngs chart. Thi s can be found i n the Speci fi ca-
ti ons secti on at the end of thi s group. A l abel stati ng
a part reference number i s attached to the generator
case. On some engi nes thi s l abel may be l ocated on
the bottom of the case. Compare thi s reference num-
ber to the Generator Rati ngs chart.
(7) Rotate the l oad control to the OFF posi ti on.
(8) Conti nue hol di ng engi ne speed at 2500. I f EVR
ci rcui try i s OK, amperage shoul d drop bel ow 1520
amps. Wi th al l el ectri cal accessori es and vehi cl e
l i ghti ng off, thi s coul d take several mi nutes of engi ne
operati on. I f amperage di d not drop, refer to the
appropri ate Powertrai n Di agnosti c Procedures man-
ual for testi ng.
(9) Remove vol t/amp tester.
I f mi ni mum amperage coul d not be met, refer to
the appropri ate Powertrai n Di agnosti c Procedures
manual for testi ng.
ON-BOARD DIAGNOSTIC SYSTEM TEST
GENERAL INFORMATION
The Powertrai n Control Modul e (PCM) moni tors
cri ti cal i nput and output ci rcui ts of the chargi ng sys-
tem, maki ng sure they are operati onal . A Di agnosti c
Troubl e Code (DTC) i s assi gned to each i nput and
output ci rcui t moni tored by the OBD system. Some
ci rcui ts are checked conti nuousl y and some are
checked onl y under certai n condi ti ons.
I f the OBD system senses that a moni tored ci rcui t
i s bad, i t wi l l put a DTC i nto el ectroni c memory. The
DTC wi l l stay i n el ectroni c memory as l ong as the
ci rcui t conti nues to be bad. The PCM i s programmed
to cl ear the memory after 50 engi ne starts i f the
probl em does not occur agai n.
Refer to Group 25, On Board Di agnosti c for more
i nformati on. A DTC descri pti on can be read usi ng the
DRB scan tool . Refer to the appropri ate Powertrai n
Di agnosti c Procedures manual for i nformati on.
A DTC does not i denti fy whi ch component i n a ci r-
cui t i s bad. Thus, a DTC shoul d be treated as a
symptom, not as the cause for the probl em. I n some
cases, because of the desi gn of the di agnosti c test
procedure, a DTC can be the reason for another DTC
to be set. Therefore, i t i s i mportant that the test pro-
cedures be fol l owed i n sequence, to understand what
caused a DTC to be set.
ERASING DIAGNOSTIC TROUBLE CODES
The DRB Scan Tool must be used to erase a DTC.
Fig. 1 Generator Terminals
Fig. 2 Battery Voltage TestTypical
VOLTAGE DROP TEST
GENERATOR2. 4L ENGINE
REMOVAL
(3) Remove accessory dri ve bel t, refer to Group 7,
Cool i ng System for proper procedures.
(4) Di sconnect the push-i n fi el d wi re connector
from back of generator (Fi g. 4).
(5) Remove nut hol di ng B+ wi re to termi nal on
back of generator.
(6) Separate B+ wi re from generator termi nal .
(7) Remove nut hol di ng top of generator to adjust-
abl e T-bol t (Fi g. 5).
(8) Remove bol t hol di ng bottom generator pi vot to
l ower mount.
(9) Remove generator.
INSTALLATION
(1) Pl ace generator i n posi ti on on vehi cl e.
(2) I nstal l bol t to hol d bottom generator pi vot to
l ower mount.
(3) I nstal l nut to hol d top of generator to adjust-
abl e T-bol t.
(4) Pl ace B+ wi re i n posi ti on on generator termi -
nal .
(5) I nstal l nut to hol d B+ wi re to termi nal on back
of generator.
(6) Connect the push-i n fi el d wi re connector onto
back of generator.
(7) I nstal l accessory dri ve bel t, refer to Group 7,
(9) Veri fy generator charge rate.
GENERATOR3. 0L ENGINE
REMOVAL
(3) Remove wi ndshi el d wi per housi ng, refer to
Group 8K, Wi ndshi el d Wi pers and Washers for
proper procedures.
(5) Remove bol t hol di ng top of generator to mount
bracket (Fi g. 6).
(6) Remove bol t hol di ng bottom of generator to
l ower pi vot bracket (Fi g. 4).
(7) Di sengage push-i n fi el d wi re connector from
back of generator.
(8) Remove nut hol di ng B+ wi re termi nal to back
of generator.
(9) Remove B+ termi nal from generator.
INSTALLATION
(1) Pl ace B+ termi nal i n posi ti on on generator.
(2) I nstal l nut to hol d B+ wi re termi nal to back of
generator
(3) Connect the push-i n fi el d wi re connector i nto
back of generator.
Fig. 3 Removal/Installation of Battery Cables
Fig. 5 Generator2.4L Engine
(4) I nstal l bol t to hol d bottom of generator to l ower
pi vot bracket.
(5) I nstal l bol t to hol d top of generator to mount
bracket.
(7) I nstal l wi ndshi el d wi per housi ng, refer to
proper procedures.
GENERATOR3. 3/3. 8 L ENGINE
REMOVAL
(3) Remove wi ndshi el d wi per housi ng, refer to
proper procedures.
(5) Remove bol t hol di ng top of generator mount
bracket to engi ne ai r i ntake pl enum (Fi g. 7).
(6) Remove bol ts hol di ng outsi de of generator
mount bracket to generator mount pl ate.
(7) Remove bol t hol di ng top of generator to mount
bracket.
(8) Remove generator mount bracket from vehi cl e.
(9) Rotate generator toward rear dash panel .
(10) Di sconnect the push-i n fi el d wi re connector
from back of generator (Fi g. 6).
(11) Remove nut hol di ng B+ wi re termi nal to back
of generator.
(12) Separate B+ termi nal from generator.
(13) Remove bol t hol di ng bottom of generator to
l ower pi vot bracket (Fi g. 8).
(14) Remove generator from vehi cl e (Fi g. 9).
INSTALLATION
(1) Pl ace generator i n posi ti on on vehi cl e.
Fig. 6 Generator3.0L Engine
Fig. 7 Generator Mounting Bracket
Fig. 8 Generator pivot Bolt
Fig. 9 Generator3.3/3.8 L Engine
(2) I nstal l bol t to hol d bottom of generator to l ower
pi vot bracket.
(3) Pl ace B+ termi nal i n posi ti on on generator.
(4) I nstal l nut to hol d B+ wi re termi nal to back of
generator.
(5) Connect the push-i n fi el d wi re connector i nto
back of generator.
(6) Rotate generator forward away from dash
panel .
(7) Pl ace generator mount bracket i n posi ti on on
vehi cl e.
(8) I nstal l bol t to hol d top of generator to mount
bracket.
(9) I nstal l bol ts to hol d outsi de of generator mount
bracket to generator mount pl ate.
(10) I nstal l bol t to hol d top of generator mount
bracket to engi ne ai r i ntake pl enum.
(12) I nstal l wi ndshi el d wi per housi ng, refer to
proper procedures.
SPECIFICATIONS
GENERATOR
Part number i s l ocated on the si de of the generator.
TORQUE
DESCRIPTION TORQUE
Battery Hol d Down Bol t. . . . . . .14 Nm (125 i n. l bs.)
Generator Mounti ng Bol ts . . . . . .54 Nm (40 ft. l bs.)
Generator B+ Termi nal . . . . . . . . .9 Nm (75 i n. l bs.)
Starter Mounti ng Bol ts . . . . . . . . .54 Nm (40 ft. l bs.)
Starter Sol enoi d Battery Nut . . . .10 Nm (90 i n. l bs.)
Type
Part Num-
ber
Amperage out-
put
Nippondenso 90 A
HS
4727220 86 Amp
Nippondenso 120 A
HS
4727221 98 Amp
IGNITION SYSTEM
CONTENTS
page page
2. 4L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3. 0L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3. 3/3. 8L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . 28
IGNITION SWITCH AND LOCK CYLINDER . . . . . 35
GENERAL INFORMATION
INDEX
page page
GENERAL INFORMATION
AUTOMATIC SHUTDOWN (ASD) RELAY . . . . . . . 4
CAMSHAFT POSITION SENSOR . . . . . . . . . . . . . 5
CRANKSHAFT POSITION SENSOR . . . . . . . . . . . 5
ENGINE COOLANT TEMPERATURE (ECT)
SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
IGNITION COIL . . . . . . . . . . . . . . . . . . . . . . . . . . 4
IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 2
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . 1
KNOCK SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . 7
LOCK KEY CYLINDER . . . . . . . . . . . . . . . . . . . . . 7
MANIFOLD ABSOLUTE PRESSURE (MAP)
SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
POWERTRAIN CONTROL MODULE . . . . . . . . . . . 1
SPARK PLUG CABLE . . . . . . . . . . . . . . . . . . . . . . 3
SPARK PLUGS2.4/3.0L . . . . . . . . . . . . . . . . . . . 2
SPARK PLUGS3.3/3.8L . . . . . . . . . . . . . . . . . . . 2
THROTTLE POSITION SENSOR (TPS) . . . . . . . . 7
CAMSHAFT POSITION SENSOR AND
CRANKSHAFT POSITION SENSOR . . . . . . . . . 11
CHECK COIL TEST2.4L . . . . . . . . . . . . . . . . . . 9
CHECK COIL TEST3.3/3.8L . . . . . . . . . . . . . . . . 9
ENGINE COOLANT TEMPERATURE SENSOR . . 11
FAILURE TO START TEST . . . . . . . . . . . . . . . . . 10
IGNITION TIMING PROCEDURE . . . . . . . . . . . . 11
INTAKE AIR TEMPERATURE SENSOR . . . . . . . . 11
SENSOR TEST . . . . . . . . . . . . . . . . . . . . . . . . 11
SPARK PLUG CONDITION . . . . . . . . . . . . . . . . . 11
TESTING FOR SPARK AT COIL2.4/3.3/3.8L
ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
TESTING FOR SPARK AT COIL3.0L . . . . . . . . . 8
THROTTLE POSITION SENSOR . . . . . . . . . . . . 13
SERVICE PROCEDURES
IGNITION TIMING PROCEDURE . . . . . . . . . . . . 15
POWERTRAIN CONTROL MODULE . . . . . . . . . . 13
SPARK PLUG GAP ADJUSTMENT . . . . . . . . . . . 13
GENERAL INFORMATION
INTRODUCTION
Thi s group descri bes the i gni ti on systems for the
2.4, 3.0, and 3.3/3.8L engi nes.
On Board Di agnosti cs i s descri bed i n Group 25 -
Emi ssi on Control Systems.
Group 0 - Lubri cati on and Mai ntenance, contai ns
general mai ntenance i nformati on for i gni ti on rel ated
i tems. The Owners Manual al so contai ns mai nte-
nance i nformati on.
POWERTRAIN CONTROL MODULE
The i gni ti on system i s regul ated by the Powertrai n
Control Modul e (PCM) (Fi g. 1). The PCM suppl i es
battery vol tage to the i gni ti on coi l through the Auto
Shutdown (ASD) Rel ay. The PCM al so control s
ground ci rcui t for the i gni ti on coi l . By swi tchi ng the
ground path for the coi l on and off, the PCM adjusts
i gni ti on ti mi ng to meet changi ng engi ne operati ng
condi ti ons.
Duri ng the crank-start peri od the PCM advances
i gni ti on ti mi ng a set amount. Duri ng engi ne opera-
ti on, the amount of spark advance provi ded by the
PCM i s determi ned by the fol l owi ng i nput factors:
NS IGNITION SYSTEM 8D - 1
avai l abl e mani fol d vacuum
barometri c pressure
engi ne cool ant temperature
engi ne RPM
i ntake ai r temperature (2.4L onl y)
throttl e posi ti on
The PCM al so regul ates the fuel i njecti on system.
Refer to the Fuel I njecti on secti ons of Group 14.
IGNITION SYSTEM
NOTE: The 2.4, 3.0 and 3.3/3.8L engines use a fixed
ignition timing system. Basic ignition timing is not
adjustable. All spark advance is determined by the
Powertrain Control Module (PCM).
The di stri butorl ess i gni ti on system used on 2.4 and
3.3/3.8L engi nes i s refered to as the Di rect I gni ti on
System (DI S). The systems three mai n components
are the coi l pack, crankshaft posi ti on sensor, and
camshaft posi ti on sensor. The crankshaft posi ti on
sensor and camshaft posi ti on sensor are hal l effect
devi ces.
The 3.0L engi ne uses a di stri butor, crankshaft sen-
sor and i gni ti on coi l . The systems mai n components
are the di stri butor, di stri butor pi ckup, camshaft si g-
nal , crankshaft si gnal and i gni ti on coi l .
SPARK PLUGS2. 4/3. 0L
Al l engi nes use resi stor spark pl ugs. They have
resi stance val ues rangi ng from 6,000 to 20,000 ohms
when checked wi th at l east a 1000 vol t spark pl ug
tester.
Do not use an ohm meter to check the resis-
tance of the spark plugs. This will give an inac-
curate reading.
Remove the spark pl ugs and exami ne them for
burned el ectrodes and foul ed, cracked or broken por-
cel ai n i nsul ators. Keep pl ugs arranged i n the order
i n whi ch they were removed from the engi ne. An i so-
l ated pl ug di spl ayi ng an abnormal condi ti on i ndi cates
that a probl em exi sts i n the correspondi ng cyl i nder.
Repl ace spark pl ugs at the i nterval s recommended i n
Group O - Lubri cati on and Mai ntenance.
Spark pl ugs that have l ow mi l eage may be cl eaned
and reused i f not otherwi se defecti ve, carbon or oi l
foul ed. Refer to the Spark Pl ug Condi ti on secti on of
thi s group. After cl eani ng, fi l e the center el ectrode
fl at wi th a smal l fl at poi nt fi l e or jewel ers fi l e. Adjust
the gap between the el ectrodes (Fi g. 2) to the di men-
si ons speci fi ed i n the chart at the end of thi s secti on.
Speci al care shoul d be used when i nstal l i ng spark
pl ugs i n the 2.4L cyl i nder head spark pl ug wel l s. Be
sure the pl ugs do not drop i nto the wel l s, damage to
the el ectrodes can occur.
Al ways ti ghten spark pl ugs to the speci fi ed torque.
Over ti ghteni ng can cause di storti on resul ti ng i n a
change i n the spark pl ug gap. Overti ghteni ng can
al so damage the cyl i nder head. Ti ghten spark pl ugs
to 28 Nm (20 ft. l bs.) torque.
SPARK PLUGS3. 3/3. 8L
The 3.3/3.8L engi nes uti l i ze pl ati num spark pl ugs.
Refer to the mai ntenance schedul e i n Group 0 of thi s
servi ce manual .
Fig. 1 Powertrain Control Module
Fig. 2 Setting Spark Plug Electrode Gap
8D - 2 IGNITION SYSTEM NS
Al l engi nes use resi stor spark pl ugs. They have
resi stance val ues rangi ng from 6,000 to 20,000 ohms
when checked wi th at l east a 1000 vol t spark pl ug
tester.
Do not use an ohm meter to check the resis-
tance of the spark plugs. This will give an inac-
curate reading.
Remove the spark pl ugs and exami ne them for
burned el ectrodes and foul ed, cracked or broken por-
cel ai n i nsul ators. Keep pl ugs arranged i n the order
i n whi ch they were removed from the engi ne. An i so-
l ated pl ug di spl ayi ng an abnormal condi ti on i ndi cates
that a probl em exi sts i n the correspondi ng cyl i nder.
Repl ace spark pl ugs at the i nterval s recommended i n
Group O - Lubri cati on and Mai ntenance.
Spark pl ugs that have l ow mi l eage may be cl eaned
and reused i f not otherwi se defecti ve, carbon or oi l
foul ed. Refer to the Spark Pl ug Condi ti on secti on of
thi s group.
The spark pl ugs are doubl e pl ati num and have a
recommended servi ce l i fe of 100,000 mi l es for normal
dri vi ng condi ti ons per schedul e A i n thi s manual . The
spark pl ugs have a recommended servi ce l i fe of
75,000 mi l es for serve dri vi ng condi ti ons per schedul e
B i n thi s manual . A thi n pl ati num pad i s wel ded to
both el ectrode ends as show i n (Fi g. 3). Extreme care
must be used to prevent spark pl ug cross threadi ng,
mi s-gapi ng and cerami c i nsul ator damage duri ng
pl ug removal and i nstal l ati on.
CAUTION: Never attempt to file the electrodes or
use a wire brush for cleaning platinum plugs. This
would damage the platinum pads which would
shorten spark plug life.
Appl y a very smal l amount of anti -sei ze compound
to the threads when rei nstal l i ng the vehi cl es ori gi nal
spark pl ugs that have been determi ned good. Do not
apply anti-seize compound to new spark plugs.
NOTE: Anti-seize compound is electrically conduc-
tive and can cause engine misfires if not applied
correctly. It is extremely important that the anti-
seize compound doesnt make contact with the
spark plug electrodes or ceramic insulator.
Never force a gap gauge between the pl ati num
el ectrodes or adjust the gap on pl ati num spark pl ugs
wi thout readi ng the 3.3/3.8L Spark Pl ug Gap Mea-
surement procedures i n thi s secti on.
Al ways ti ghten spark pl ugs to the speci fi ed torque.
Over ti ghteni ng can cause di storti on resul ti ng i n a
change i n the spark pl ug gap. Overti ghteni ng can
al so damage the cyl i nder head. Ti ghten spark pl ugs
to 28 Nm (20 ft. l bs.) torque.
Due to the engi ne packagi ng envi ronment for the
3.3/3.8L engi nes, extreme care shoul d be used when
i nstal l i ng the spark pl ugs to avoi d cross threadi ng
probl ems.
3.3/3.8L SPARK PLUG GAP MEASUREMENT
CAUTION: The Platinum pads can be damaged dur-
ing the measurement of checking the gap if extreme
care is not used.
USE ONLY A TAPER GAP GAUGE (Fig. 2)
Never force the gap gauge through the pl ati num
pads. Onl y appl y enough force unti l resi stance i s fel t.
Never use a wi re brush or spark pl ug cl eaner
machi ne to cl ean pl ati num spark pl ugs
Use an OSHA approved ai r nozzl e when dryi ng
gas foul ed spark pl ugs.
I f gap adjustment i s requi red of pl ati num pl ug,
bend onl y the ground el ectrode. DO NOT TOUCH
the pl ati num pads. Use onl y a proper gappi ng tool
and check wi th a taper gap gauge.
CAUTION: Cleaning of the platinum plug may dam-
age the platinum tip.
SPARK PLUG CABLE
Spark Pl ug cabl es are someti mes referred to as
secondary i gni ti on wi res. The wi res transfer el ectri -
cal current from the i gni ti on coi l pack, di stri butor
(3.0L), to i ndi vi dual spark pl ugs at each cyl i nder. The
resi sti ve spark pl ug cabl es are of nonmetal l i c con-
structi on. The cabl es provi de suppressi on of radi o fre-
quency emi ssi ons from the i gni ti on system.
Check the spark pl ug cabl e connecti ons for good
contact at the coi l , di stri butor cap towers (3.0L), and
spark pl ugs. Termi nal s shoul d be ful l y seated. The
i nsul ators shoul d be i n good condi ti on and shoul d fi t
ti ghtl y on the coi l , di stri butor (3.0L) and spark pl ugs.
Spark pl ug cabl es wi th i nsul ators that are cracked or
torn must be repl aced.
Fig. 3 Platinum Pads
Cl ean Spark Pl ug cabl es wi th a cl oth moi stened
wi th a non-fl ammabl e sol vent. Wi pe the cabl es dry.
Check for bri ttl e or cracked i nsul ati on.
SPARK PLUG CABLES3.3/3.8L
The spark pl ug cabl es and spark pl ug boots are
made from hi gh temperature si l i cone materi al s. The
spark pl ug boots uti l i ze metal heat shi el ds for ther-
mal protecti on from the exhaust mani fol d. The heat
shi el ds sl i de over the spark pl ug boots. The notches
on the heat shi el ds ensure the spark pl ug boot and
shi el d twi st together duri ng spark pl ug boot removal .
They al so i denti fy proper heat shi el d i nstal l ati on on
the boot for servi ce. Refer to 3.3/3.8L Spark Plug
Cable removal and installation. Al l spark pl ug
cabl e l eads are properl y i denti fi ed wi th cyl i nder num-
bers. The i nsi de of the spark pl ug boot i s coated wi th
a speci al hi gh temperature si l i cone grease for greater
seal i ng and to mi ni mi ze boot bondi ng to the spark
pl ug i nsul ator. The convol uted tubi ng on the rear
pl ug cabl es are made of a hi gh temperature pl asti c
materi al . Under normal dri vi ng condi ti ons, the spark
pl ug cabl es have a recommended servi ce l i fe of a
100,000 mi l es. The spark pl ugs have a recommended
servi ce l i fe of 75,000 mi l es for severe dri vi ng condi -
ti ons per schedul e B i n thi s manual .
The spark pl ug heat shi el d can be reused i f an
i gni ti on cabl e i s repl aced due to fai l ure. Never reuse
heat shi el ds that have heat shi el d anti -twi st, si de or
spark pl ug attachment tabs bent or mi ssi ng. Ensure
that the heat shi el d i s properl y attached to the spark
pl ug to avoi d RFI probl ems. The bottom of the spark
pl ug heat shi el d must make contact wi th the spark
pl ug hex.
The front i gni ti on cabl es must not make contact
wi th the oi l di p sti ck tube and #5 cabl e must not
touch the coi l mounti ng bol t to avoi d abrasi on/di el ec-
tri c fai l ures.
IGNITION COIL
WARNING: THE DIRECT IGNITION SYSTEM GEN-
ERATES APPROXIMATELY 40,000 VOLTS. PER-
SONAL INJURY COULD RESULT FROM CONTACT
WITH THIS SYSTEM.
The i gni ti on coi l assembl y consi sts of 3 i ndepen-
dent coi l s mol ded together (Fi g. 4). The coi l assembl y
i s mounted on the i ntake mani fol d. Spark pl ug cabl es
route to each cyl i nder from the coi l . The coi l fi res two
spark pl ugs every power stroke. One pl ug i s the cyl -
i nder under compressi on, the other cyl i nder fi res on
the exhaust stroke. The Powertrai n Control Modul e
(PCM) determi nes whi ch of the coi l s to charge and
fi re at the correct ti me.
Coi l 1 fi res cyl i nders 1 and 4, coi l 2 fi res cyl i nders
2 and 5, coi l 3 fi res cyl i nders 3 and 6.
The Auto Shutdown (ASD) rel ay provi des battery
vol tage to the i gni ti on coi l . The PCM provi des a
ground contact (ci rcui t) for energi zi ng the coi l . When
the PCM breaks the contact, the energy i n the coi l
pri mary transfers to the secondary causi ng the
spark. The PCM wi l l de-energi ze the ASD rel ay i f i t
does not recei ve the crankshaft posi ti on sensor and
camshaft posi ti on sensor i nputs. Refer to Auto Shut-
down (ASD) Rel ayPCM Output, i n thi s secti on for
rel ay operati on.
AUTOMATIC SHUTDOWN (ASD) RELAY
The Powertrai n Control Modul e (PCM) operates
the Auto Shutdown (ASD) rel ay by swi tchi ng the
ground path on and off.
The ASD rel ay suppl i es battery vol tage to the fuel
i njectors, el ectroni c i gni ti on coi l and the heati ng el e-
ments i n the oxygen sensors.
The PCM control s the rel ay by swi tchi ng the
ground path for the sol enoi d si de of the rel ay on and
off. The PCM turns the ground path off when the
i gni ti on swi tch i s i n the Off posi ti on unl ess the 02
Heater Moni tor test i s bei ng run. Refer to Group 25,
On-Board Di agnosti cs. When the i gni ti on swi tch i s i n
the On or Crank posi ti on, the PCM moni tors the
crankshaft posi ti on sensor and camshaft posi ti on sen-
sor si gnal s to determi ne engi ne speed and i gni ti on
ti mi ng (coi l dwel l ). I f the PCM does not recei ve the
sor si gnal s when the i gni ti on swi tch i s i n the Run
posi ti on, i t wi l l de-energi ze the ASD rel ay.
The ASD rel ay i s l ocated i n the Power Di stri buti on
Center (PDC). The PDC i s l ocated on the dri vers
si de i nner fender wel l (Fi g. 5). A l abel on the under-
si de of the PDC cover i denti fi es the rel ays and fuses
i n the PDC.
Fig. 4 Ignition Coil Pack
CRANKSHAFT POSITION SENSOR
The crankshaft posi ti on sensor detects sl ots cut
i nto the transmi ssi on dri vepl ate extensi on (Fi g. 6).
There are 3 sets of sl ots. Each set contai ns 4 sl ots,
for a total of 12 sl ots (Fi g. 7). Basi c ti mi ng i s set by
the posi ti on of the l ast sl ot i n each group. Once the
Powertrai n Control Modul e (PCM) senses the l ast
sl ot, i t determi nes crankshaft posi ti on (whi ch pi ston
wi l l next be at TDC) from the camshaft posi ti on sen-
sor i nput. The 4 pul ses generated by the crankshaft
posi ti on sensor represent the 69, 49, 29, and 9
BTDC marks. I t may take the PCM one engi ne rev-
ol uti on to determi ne crankshaft posi ti on.
The PCM uses crankshaft posi ti on reference to
determi ne i njector sequence, i gni ti on ti mi ng and the
presence of mi sfi re. Once the PCM determi nes crank-
shaft posi ti on, i t begi ns energi zi ng the i njectors i n
sequence.
The crankshaft sensor i s l ocated on the passengers
si de of the transmi ssi on housi ng, above the di fferen-
ti al housi ng (Fi g. 8). The bottom of the sensor i s posi -
ti oned next to the dri ve pl ate.
CAMSHAFT POSITION SENSOR
The camshaft posi ti on sensor provi des cyl i nder
i denti fi cati on to the Powertrai n Control Modul e
(PCM) (Fi g. 9). The sensor generates pul ses as
groups of notches on the camshaft sprocket pass
underneath i t (Fi g. 10). The PCM keeps track of
crankshaft rotati on and i denti fi es each cyl i nder by
the pul ses generated by the notches on the camshaft
sprocket. Four crankshaft pul ses fol l ow each group of
camshaft pul ses.
When the PCM recei ves 2 cam pul ses fol l owed by
the l ong fl at spot on the camshaft sprocket, i t knows
that the crankshaft ti mi ng marks for cyl i nder 1 are
next (on dri vepl ate). When the PCM recei ves one
camshaft pul se after the l ong fl at spot on the
sprocket, cyl i nder number 2 crankshaft ti mi ng marks
are next. After 3 camshaft pul ses, the PCM knows
Fig. 5 Power Distribution Center
Fig. 6 Crankshaft Position Sensor
Fig. 7 Timing Slots
Fig. 8 Crankshaft Position Sensor Location
cyl i nder 4 crankshaft ti mi ng marks fol l ow. One cam-
shaft pul se after the 3 pul ses i ndi cates cyl i nder 5.
The 2 camshaft pul ses after cyl i nder 5 si gnal s cyl i n-
der 6 (Fi g. 10). The PCM can synchroni ze on cyl i n-
ders 1 or 4.
When metal al i gns wi th the sensor, vol tage goes
l ow (l ess than 0.3 vol ts). When a notch al i gns wi th
the sensor, vol tage swi tches hi gh (5.0 vol ts). As a
group of notches pass under the sensor, the vol tage
swi tches from l ow (metal ) to hi gh (notch) then back
to l ow. The number of notches determi ne the amount
of pul ses. I f avai l abl e, an osci l l oscope can di spl ay the
square wave patterns of each ti mi ng event.
Top Dead Center (TDC) does not occur when
notches on the camshaft sprocket pass bel ow the cyl -
i nder. TDC occurs after the camshaft pul se (or
pul ses) and after the 4 crankshaft pul ses associ ated
wi th the parti cul ar cyl i nder. The arrows and cyl i nder
cal l outs on Fi gure 4 represent whi ch cyl i nder the
fl at spot and notches i denti fy, they do not i ndi cate
TDC posi ti on.
The camshaft posi ti on sensor i s mounted i n the
front of the ti mi ng case cover (Fi g. 11).
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR
The MAP sensor reacts to absol ute pressure i n the
i ntake mani fol d and provi des an i nput vol tage to the
Powertrai n Control Modul e (PCM). As engi ne l oad
changes, mani fol d pressure vari es. The changes i n
engi ne l oad cause the MAP sensors resi stance to
change. The change i n MAP sensor resi stance resul ts
i n a di fferent i nput vol tage to the PCM.
The i nput vol tage l evel suppl i es the PCM wi th
i nformati on rel ati ng to ambi ent barometri c pressure
duri ng engi ne start-up (cranki ng) and engi ne l oad
whi l e i ts operati ng. Based on MAP sensor vol tage
and i nputs from other sensors, the PCM adjusts
spark advance and the ai r-fuel mi xture.
ENGINE COOLANT TEMPERATURE (ECT) SENSOR
The ECT sensor i s l ocated next to the thermostat
housi ng (Fi g. 12). The sensor provi des an i nput vol t-
age to the Powertrai n Control Modul e (PCM). The
sensor i s a vari abl e resi stance (thermi stor) wi th a
range of -40F to 265F. As cool ant temperature var-
i es, the sensors resi stance changes, resul ti ng i n a di f-
ferent i nput vol tage to the PCM.
The PCM contai ns di fferent spark advance sched-
ul es for col d and warm engi ne operati on. The sched-
ul es reduce engi ne emi ssi on and i mprove dri veabi l i ty.
When the engi ne i s col d, the PCM wi l l demand
sl i ghtl y ri cher ai r-fuel mi xtures and hi gher i dl e
speeds unti l normal operati ng temperatures are
reached.
The ECT sensor i nput i s al so used for cool i ng fan
control .
Fig. 9 Camshaft Position Sensor
Fig. 10 Camshaft Sprocket
Fig. 11 Camshaft Position Sensor Location
THROTTLE POSITION SENSOR (TPS)
The TPS mounts to the si de of the throttl e body
(Fi g. 13).
The TPS connects to the throttl e bl ade shaft. The
TPS i s a vari abl e resi stor that provi des the Power-
trai n Control Modul e (PCM) wi th an i nput si gnal
(vol tage). The si gnal represents throttl e bl ade posi -
ti on. As the posi ti on of the throttl e bl ade changes,
the resi stance of the TPS changes.
The PCM suppl i es approxi matel y 5 vol ts to the
TPS. The TPS output vol tage (i nput si gnal to the
powertrai n control modul e) represents throttl e bl ade
posi ti on. The TPS output vol tage to the PCM vari es
from approxi matel y 0.40 vol t at mi ni mum throttl e
openi ng (i dl e) to a maxi mum of 3.80 vol ts at wi de
open throttl e.
Al ong wi th i nputs from other sensors, the PCM
uses the TPS i nput to determi ne current engi ne oper-
ati ng condi ti ons. The PCM al so adjusts fuel i njector
pul se wi dth and i gni ti on ti mi ng based on these
i nputs.
LOCK KEY CYLINDER
The l ock cyl i nder i s i nserted i n the end of the
housi ng opposi te the i gni ti on swi tch. The i gni ti on key
rotates the cyl i nder to 5 di fferent detents (Fi g. 14):
Accessory
Off (l ock)
Unl ock
On/Run
Start
KNOCK SENSOR
The knock sensor threads i nto the si de of the cyl -
i nder bl ock i n front of the starter motor. When the
knock sensor detects a knock i n one of the cyl i nders,
i t sends an i nput si gnal to the PCM. I n response, the
PCM retards i gni ti on ti mi ng for al l cyl i nders by a
schedul ed amount.
Knock sensors contai n a pi ezoel ectri c materi al
whi ch constantl y vi brates and sends an i nput vol tage
(si gnal ) to the PCM whi l e the engi ne operates. As the
i ntensi ty of the crystal s vi brati on i ncrease, the knock
sensor output vol tage al so i ncreases.
Fig. 12 Engine Coolant Temperature Sensor3.3/
3.8L
Fig. 13 Throttle Position Sensor and Idle Air Control
Motor
Fig. 14 Ignition Lock Cylinder Detents
NOTE: Over or under tightening effects knock sen-
sor performance, possibly causing improper spark
control.
TESTING FOR SPARK AT COIL2. 4/3. 3/3. 8L
ENGINES
WARNING: THE DIRECT IGNITION SYSTEMS GEN-
ERATES APPROXIMATELY 40,000 VOLTS. PER-
SONAL INJURY COULD RESULT FROM CONTACT
WITH THIS SYSTEM.
The coi l pack contai ns i ndependent coi l s. Each coi l
must be checked i ndi vi dual l y.
CAUTION: Spark plug wire damage may occur if
the spark plug is moved more than 1/4 inch away
from the engine ground.
CAUTION: Do not leave any one spark plug cable
disconnected any longer than 30 seconds or possi-
ble heat damage to catalytic converter will occur.
CAUTION: Test must be performed at idle and in
park only with the parking brake on.
Use a new spark plug and spark plug cable
for the following test.
(1) I nsert a new spark pl ug i nto the new spark
pl ug boot. Ground the pl ug to the engi ne (Fi g. 15).
Do not hol d wi th your hand.
(2) Starti ng wi th coi l i nsul ator #1, remove i t from
the DI S coi l .
(3) Pl ug the test spark pl ug cabl e onto #1 coi l
tower. Make sure a good connecti on i s made; there
shoul d be a cl i ck sound.
(4) Crank the engi ne and l ook for spark across the
el ectrodes of the spark pl ug.
CAUTION: Always install the cable back on the coil
tower after testing to avoid damage to the coil and
catalytic converter.
(5) Repeat the above test for the remai ni ng coi l s. I f
there i s no spark duri ng al l cyl i nder tests, proceed to
the Fai l ure To Start Test.
(6) I f one or more tests i ndi cate i rregul ar, weak, or
no spark, proceed to Check Coi l Test.
TESTING FOR SPARK AT COIL3. 0L
WARNING: APPLY PARKING BRAKE AND/OR
BLOCK THE WHEELS BEFORE PERFORMING ANY
TEST WITH THE ENGINE RUNNING.
CAUTION: Spark plug cables may be damaged if
this test is performed with more than 1/4 inch clear-
ance between the cable and engine ground.
Remove the coi l secondary cabl e from the di stri bu-
tor cap. Hol d the end of cabl e about 6 mm (1/4-i nch)
away from a good engi ne ground usi ng non-conduc-
ti ve i gni ti on pl i ers (Fi g. 16). Crank the engi ne and
i nspect for spark at the coi l secondary cabl e.
There must be a constant spark at the coi l second-
ary cabl e. I f spark i s not constant or there i s no
spark, proceed to the fai l ure to start test. I f the
spark i s constant, conti nue to crank engi ne and,
whi l e sl owl y movi ng coi l secondary cabl e away from
ground, l ook for arci ng at the coi l tower. I f arci ng
occurs at the tower, repl ace the coi l .
I f a constant spark i s present and no arci ng occurs
at the coi l tower, the i gni ti on system i s produci ng the
necessary hi gh secondary vol tage. However, make
Fig. 15 Testing For Spark
Fig. 16 Checking for Spark
sure that the spark pl ugs are fi ri ng. I nspect the di s-
tri butor rotor, cap, spark pl ug cabl es, and spark
pl ugs. I f they are i n proper worki ng order, the i gni -
ti on system i s not the reason why the engi ne wi l l not
start. I nspect the fuel system and engi ne for proper
operati on.
CHECK COIL TEST2. 4L
Coil one fires cylinders 1 and 4, coil two fires
cylinders 2 and 3. Each coil tower is labeled
with the number of the corresponding cylinder.
(1) Remove i gni ti on cabl es and measure the resi s-
tance of the cabl es. Resi stance must be wi thi n the
range shown i n the Cabl e Resi stance Chart i n Spec-
i fi cati ons. Repl ace any cabl e not wi thi n tol erance.
(2) Di sconnect the el ectri cal connector from the
coi l pack.
(3) Measure the pri mary resi stance of each coi l . At
the coi l , connect an ohmmeter between the B+ pi n
and the pi n correspondi ng to the cyl i nders i n ques-
ti on (Fi g. 17). Resi stance on the pri mary si de of each
coi l shoul d be 0.45 - 0.65 ohm at (70 to 80 F).
Repl ace the coi l i f resi stance i s not wi thi n tol erance.
(4) Remove i gni ti on cabl es from the secondary tow-
ers of the coi l . Measure the secondary resi stance of
the coi l between the towers of each i ndi vi dual coi l
(Fi g. 18). Secondary resi stance shoul d be 7,000 to
15,800 ohms. Repl ace the coi l i f resi stance i s not
wi thi n tol erance.
CHECK COIL TEST3. 3/3. 8L
Coil 1 fires cylinders 1 and 4, coil 2 fires cyl-
inders 2 and 5, and coil 3 fires cylinders 3 and
6. Each coil tower is labeled with the number of
the corresponding cylinder.
coi l pack (Fi g. 19).
(2) Measure the pri mary resi stance of each coi l . At
the coi l , connect an ohmmeter between the B+ pi n
and the pi n correspondi ng to the cyl i nders i n ques-
ti on (Fi g. 20). Resi stance on the pri mary si de of each
coi l shoul d be 0.45 - 0.65 ohm at 21 to 27C (70 to
80F). A coi l that has not been al l owed to cool off,
woul d resul t i n i naccurate measurement resul ts.
Repl ace the coi l i f resi stance i s not wi thi n tol erance.
Fig. 17 Terminal Identification
Fig. 18 Checking Ignition Coil Secondary
Resistance
Fig. 19 Ignition Coil Electrical Connector
Fig. 20 Ignition Coil Terminal Identification
(3) Remove i gni ti on cabl es from the secondary tow-
ers of the coi l . Measure the secondary resi stance of
the coi l between the towers of each i ndi vi dual coi l
(Fi g. 21). Secondary resi stance shoul d be 7,000 to
15,800 ohms. Repl ace the coi l i f resi stance i s not
wi thi n tol erance.
FAILURE TO START TEST
Thi s no-start test checks the camshaft posi ti on sen-
sor and crankshaft posi ti on sensor.
The Powertrai n Control Modul e (PCM) suppl i es 8
vol ts to the camshaft posi ti on sensor and crankshaft
posi ti on sensor through one ci rcui t. I f the 8 vol t sup-
pl y ci rcui t shorts to ground, nei ther sensor wi l l pro-
duce a si gnal (output vol tage to the PCM).
When the i gni ti on key i s turned and l eft i n the On
posi ti on, the PCM automati cal l y energi zes the Auto
Shutdown (ASD) rel ay. However, the control l er de-en-
ergi zes the rel ay wi thi n one second because i t has
not recei ved a camshaft posi ti on sensor si gnal i ndi -
cati ng engi ne rotati on.
Duri ng cranki ng, the ASD rel ay wi l l not energi ze
unti l the PCM recei ves a camshaft posi ti on sensor
si gnal . Secondl y, the ASD rel ay remai ns energi zed
onl y i f the control l er senses a crankshaft posi ti on
sensor si gnal i mmedi atel y after detecti ng the cam-
shaft posi ti on sensor si gnal .
(1) Check battery vol tage. Vol tage shoul d be
approxi matel y 12.66 vol ts or hi gher to perform fai l -
ure to start test.
(2) Di sconnect the harness connector from the coi l
pack.
(3) Connect a test l i ght to the B+ (battery vol tage)
termi nal of the coi l el ectri cal connector and ground
as shown i n (Fi g. 22). The B+ wi re for the DI S coi l i s
dark green wi th an orange tracer. Do not spread
the terminal with the test light probe.
(4) Turn the i gni ti on key to the ON position. The
test l i ght shoul d fl ash On and then Off. Do not turn
the Key to off position, leave it in the On posi-
tion.
(a) I f the test l i ght fl ashes momentari l y, the
PCM grounded the Auto Shutdown (ASD) rel ay.
Proceed to step 5.
(b) I f the test l i ght di d not fl ash, the ASD rel ay
di d not energi ze. The cause i s ei ther the rel ay or
one of the rel ay ci rcui ts. Use the DRB scan tool to
test the ASD rel ay and ci rcui ts. Refer to the appro-
pri ate Powertrai n Di agnosti cs Procedure Manual .
Refer to the wi ri ng di agrams secti on for ci rcui t
i nformati on.
(5) Crank the engi ne. (I f the key was pl aced i n the
off posi ti on after step 4, pl ace the key i n the On posi -
ti on before cranki ng. Wai t for the test l i ght to fl ash
once, then crank the engi ne.)
(6) I f the test l i ght momentari l y fl ashes duri ng
cranki ng, the PCM i s not recei vi ng a crankshaft posi -
ti on sensor si gnal . Use the DRB scan tool to test the
crankshaft posi ti on sensor and sensor ci rcui ts. Refer
to the appropri ate Powertrai n Di agnosti cs Procedure
Manual . Refer to the wi ri ng di agrams secti on for ci r-
cui t i nformati on.
(7) I f the test l i ght di d not fl ash duri ng cranki ng,
unpl ug the crankshaft posi ti on sensor connector.
Turn the i gni ti on key to the off posi ti on. Turn the
key to the On posi ti on, wai t for the test l i ght to
momentari l y fl ash once, then crank the engi ne. I f the
test l i ght momentari l y fl ashes, the crankshaft posi -
ti on sensor i s shorted and must be repl aced. I f the
l i ght di d not fl ash, the cause of the no-start i s i n
Fig. 21 Checking Ignition Coil Secondary
Resistance
Fig. 22 Ignition Coil Engine Harness Connector
ei ther the crankshaft posi ti on sensor/camshaft posi -
ti on sensor 8 vol t suppl y ci rcui t, or the camshaft
posi ti on sensor output or ground ci rcui ts. Use the
DRB scan tool to test the camshaft posi ti on sensor
and the sensor ci rcui ts. Refer to the appropri ate Pow-
ertrai n Di agnosti cs Procedure Manual . Refer to the
wi ri ng di agrams secti on for ci rcui t i nformati on.
IGNITION TIMING PROCEDURE
The engi nes for thi s vehi cl e, use a fi xed i gni ti on
system. The PCM regul ates i gni ti on ti mi ng. Basi c
i gni ti on ti mi ng i s not adjustabl e.
TEST
Refer to Group 14, Fuel System for Di agnosi s and
Testi ng.
CAMSHAFT POSITION SENSOR AND CRANKSHAFT
POSITION SENSOR
The output vol tage of a properl y operati ng cam-
shaft posi ti on sensor or crankshaft posi ti on sensor
swi tches from hi gh (5.0 vol ts) to l ow (0.3 vol ts). By
connecti ng an Moper Di agonosti c System (MDS) and
engi ne anal yzer to the vehi cl e, techni ci ans can vi ew
the square wave pattern.
ENGINE COOLANT TEMPERATURE SENSOR
Refer to Group 14, Fuel System for Di agnosi s and
Testi ng.
INTAKE AIR TEMPERATURE SENSOR
Refer to Group 14, Fuel System, for Di agnosi s and
Testi ng.
SPARK PLUG CONDITION
NORMAL OPERATING CONDITIONS
The few deposi ts present wi l l be probabl y l i ght tan
or sl i ghtl y gray i n col or wi th most grades of commer-
ci al gasol i ne (Fi g. 23). There wi l l not be evi dence of
el ectrode burni ng. Gap growth wi l l not average more
than approxi matel y 0.025 mm (.001 i n) per 1600 km
(1000 mi l es) of operati on for non pl ati num spark
pl ugs. Non-pl atni um spark pl ugs that have normal
wear can usual l y be cl eaned, have the el ectrodes fi l ed
and regapped, and then rei nstal l ed.
CAUTION: Never attempt to file the electrodes or
use a wire brush for cleaning platinum spark plugs.
This would damage the platinum pads which would
shorten spark plug life.
Some fuel refi ners i n several areas of the Uni ted
States have i ntroduced a manganese addi ti ve (MMT)
for unl eaded fuel . Duri ng combusti on, fuel wi th MMT
may coat the enti re ti p of the spark pl ug wi th a rust
col ored deposi t. The rust col or deposi ts can be mi sdi -
agnosed as bei ng caused by cool ant i n the combusti on
chamber. Spark pl ug performance i s not affected by
MMT deposi ts.
COLD FOULING (CARBON FOULING)
Col d foul i ng i s someti mes referred to as carbon
foul i ng because the deposi ts that cause col d foul i ng
are basi cal l y carbon (Fi g. 23). A dry, bl ack deposi t on
one or two pl ugs i n a set may be caused by sti cki ng
val ves or mi sfi re condi ti ons. Col d (carbon) foul i ng of
the enti re set may be caused by a cl ogged ai r cl eaner.
Col d foul i ng i s normal after short operati ng peri -
ods. The spark pl ugs do not reach a hi gh enough
operati ng temperature duri ng short operati ng peri -
ods. Replace carbon fouled plugs with new
spark plugs.
FUEL FOULING
A spark pl ug that i s coated wi th excessi ve wet fuel
i s cal l ed fuel foul ed. Thi s condi ti on i s normal l y
observed duri ng hard start peri ods. Clean fuel
fouled spark plugs with compressed air and
reinstall them in the engine.
OIL FOULING
A spark pl ug that i s coated wi th excessi ve wet oi l
i s oi l foul ed. I n ol der engi nes, wet foul i ng can be
caused by worn ri ngs or excessi ve cyl i nder wear.
Break-i n foul i ng of new engi nes may occur before
normal oi l control i s achi eved. Replace oil fouled
spark plugs with new ones.
OIL OR ASH ENCRUSTED
I f one or more pl ugs are oi l or ash encrusted, eval -
uate the engi ne for the cause of oi l enteri ng the com-
busti on chambers (Fi g. 24). Someti mes fuel addi ti ves
can cause ash encrustati on on an enti re set of spark
Fig. 23 Normal Operation and Cold (Carbon) Fouling
pl ugs. Ash encrusted spark plugs can be cleaned
and reused.
HIGH SPEED MISS
When repl aci ng spark pl ugs because of a hi gh
speed mi ss condi ti on; wide open throttle opera-
tion should be avoided for approximately 80 km
(50 miles) after installation of new plugs. Thi s
wi l l al l ow deposi t shi fti ng i n the combusti on chamber
to take pl ace gradual l y and avoi d pl ug destroyi ng
spl ash foul i ng shortl y after the pl ug change.
ELECTRODE GAP BRIDGING
Loose deposi ts i n the combusti on chamber can
cause el ectrode gap bri dgi ng. The deposi ts accumu-
l ate on the spark pl ugs duri ng conti nuous stop-
and-go dri vi ng. When the engi ne i s suddenl y
subjected to a hi gh torque l oad, the deposi ts parti al l y
l i quefy and bri dge the gap between the el ectrodes
(Fi g. 25). Thi s short ci rcui ts the el ectrodes. Spark
plugs with electrode gap bridging can be
cleaned and reused.
SCAVENGER DEPOSITS
Fuel scavenger deposi ts may be ei ther whi te or yel -
l ow (Fi g. 26). They may appear to be harmful , but
are a normal condi ti on caused by chemi cal addi ti ves
i n certai n fuel s. These addi ti ves are desi gned to
change the chemi cal nature of deposi ts and decrease
spark pl ug mi sfi re tendenci es. Noti ce that accumul a-
ti on on the ground el ectrode and shel l area may be
heavy but the deposi ts are easi l y removed. Spark
plugs with scavenger deposits can be consid-
ered normal in condition, cleaned and reused.
CHIPPED ELECTRODE INSULATOR
A chi pped el ectrode i nsul ator usual l y resul ts from
bendi ng the center el ectrode whi l e adjusti ng the
spark pl ug el ectrode gap. Under certai n condi ti ons,
severe detonati on al so can separate the i nsul ator
from the center el ectrode (Fi g. 27). Spark plugs
with chipped electrode insulators must be
replaced.
PREIGNITION DAMAGE
Excessi ve combusti on chamber temperature can
cause prei gni ti on damage. Fi rst, the center el ectrode
di ssol ves and the ground el ectrode di ssol ves some-
what l ater (Fi g. 28). I nsul ators appear rel ati vel y
deposi t free. Determi ne i f the spark pl ugs are the
correct type, as speci fi ed on the VECI l abel , or i f
other operati ng condi ti ons are causi ng engi ne over-
heati ng.
SPARK PLUG OVERHEATING
Overheati ng i s i ndi cated by a whi te or gray center
el ectrode i nsul ator that al so appears bl i stered (Fi g.
Fig. 24 Oil or Ash Encrusted
Fig. 25 Electrode Gap Bridging
Fig. 26 Scavenger Deposits
29). The i ncrease i n el ectrode gap wi l l be consi der-
abl y i n excess of 0.001 i n per 1000 mi l es of operati on.
Thi s suggests that a pl ug wi th a cool er heat range
rati ng shoul d be used. Over advanced i gni ti on ti m-
i ng, detonati on and cool i ng system mal functi ons al so
can cause spark pl ug overheati ng.
THROTTLE POSITION SENSOR
To perform a compl ete test of the thi s sensor and
i ts ci rcui try, refer to the DRB scan tool and appropri -
ate Powertrai n Di agnosti cs Procedures manual . To
test the throttl e posi ti on sensor onl y, refer to the fol -
l owi ng:
The Throttl e Posi ti on Sensor (TPS) can be tested
wi th a di gi tal vol tmeter (DVM). The center termi nal
of the sensor i s the output termi nal . One of the other
termi nal s i s a 5 vol t suppl y and the remai ni ng ter-
mi nal i s ground.
Connect the DVM between the center and sensor
ground termi nal . Refer to Group 8W - Wi ri ng Di a-
grams for correct pi nout.
Wi th the i gni ti on swi tch i n the ON posi ti on, check
the output vol tage at the center termi nal wi re of the
connector. Check the output vol tage at i dl e and at
Wi de-Open-Throttl e (WOT). At i dl e, TPS output vol t-
age shoul d be approxi matel y 0.38 vol ts to 1.2 vol ts.
At wi de open throttl e, TPS output vol tage shoul d be
approxi matel y 3.1 vol ts to 4.4 vol ts. The output vol t-
age shoul d gradual l y i ncrease as the throttl e pl ate
moves sl owl y from i dl e to WOT.
Check for spread termi nal s at the sensor and PCM
connecti ons before repl aci ng the TPS.
SERVICE PROCEDURES
SPARK PLUG GAP ADJUSTMENT
Check the spark pl ug gap wi th a gap gauge. I f the
gap i s not correct, adjust i t by bendi ng the ground
el ectrode (Fi g. 30).
CAUTION: The Platinum pads can be damaged dur-
ing the measurement of checking the gap if extreme
care is not used.
Refer to 3.3/3.8L Spark Pl ug Gap Measurment i n
thi s secti on.
REMOVAL
(1) Di sconnect both cabl es from battery, negati ve
cabl e fi rst.
(2) Remove 2 screws hol di ng Power Di stri buti on
Center (PDC) to bracket (Fi g. 31).
(3) Remove heat shi el d from battery (Fi g. 32).
(4) Remove nut and cl amp hol di ng battery to bat-
tery tray (Fi g. 33).
(5) Remove battery from vehi cl e.
(6) Rotate PDC toward center of vehi cl e to remove
from rear bracket (Fi g. 34).
Fig. 27 Chipped Electrode Insulator
Fig. 28 Preignition Damage
Fig. 29 Spark Plug Overheating
(7) Pul l PDC rearward to remove from front
bracket. Lay PDC asi de to al l ow access to Powertrai n
Control Modul e (PCM).
(8) Squeeze tabs on 40-way connector. Pul l connec-
tor rearward to remove from PCM (Fi g. 35). Remove
both way connectors.
(9) Remove 3 screws hol di ng PCM to fender (Fi g.
36).
(10) Remove PCM from vehi cl e.
INSTALLATION
(1) Connect 2 40-Way el ectri cal connectors to PCM
(Fi g. 35).
(2) I nstal l PCM. Ti ghten mounti ng screws.
(3) I nstal l PDC bracket.
(4) I nstal l battery.
Fig. 30 Setting Spark Plug Electrode GapTypical
Fig. 31 Power Distribution Center Retaining Screws
Fig. 33 Battery Clamp
IGNITION TIMING PROCEDURE
The 2.4, 3.0, and 3.3/3.8L engi nes use a fi xed i gni -
ti on system. Basi c i gni ti on ti mi ng i s not adjustabl e.
The Powertrai n Control Modul e (PCM) regul ates
i gni ti on ti mi ng.
Fig. 34 PDC Rear Bracket
Fig. 35 PCM 40-Way Connectors
Fig. 36 PCM Removal/Installation
2.4L ENGINE
INDEX
page page
CAMSHAFT POSITION SENSOR . . . . . . . . . . . . 17
CRANKSHAFT POSITION SENSOR . . . . . . . . . . 16
FIRING ORDER2.4L . . . . . . . . . . . . . . . . . . . . 16
INTAKE AIR TEMPERATURE SENSOR2.4L . . . 17
2.4L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
IGNITION COIL2.4L . . . . . . . . . . . . . . . . . . . . . 18
KNOCK SENSOR2.4L . . . . . . . . . . . . . . . . . . . 21
SENSOR2.4/3.3/3.8L . . . . . . . . . . . . . . . . . . 20
SPARK PLUG CABLE SERVICE2.4L . . . . . . . . 18
SPARK PLUG SERVICE . . . . . . . . . . . . . . . . . . . 18
SPECIFICATIONS
IGNITION COIL . . . . . . . . . . . . . . . . . . . . . . . . . 22
SPARK PLUG CABLE RESISTANCE2.4L . . . . . 22
SPARK PLUG . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
FIRING ORDER2. 4L
The PCM determi nes what cyl i nder to fi re from the
crankshaft posi ti on sensor i nput and the camshaft
posi ti on sensor i nput. The second crankshaft counter-
wei ght has machi ned i nto i t two sets of four ti mi ng
reference notches and a 60 degree si gnature notch
(Fi g. 1). From the crankshaft posi ti on sensor i nput
the PCM determi nes engi ne speed and crankshaft
angl e (posi ti on).
The notches generate pul ses from hi gh to l ow i n
the crankshaft posi ti on sensor output vol tage. When
a metal porti on of the counterwei ght al i gns wi th the
crankshaft posi ti on sensor, the sensor output vol tage
goes l ow (l ess than 0.3 vol ts). When a notch al i gns
wi th the sensor, vol tage swi tches hi gh (5.0 vol ts). As
a group of notches pass under the sensor, the output
vol tage swi tches from l ow (metal ) to hi gh (notch)
then back to l ow.
I f avai l abl e, an osci l l oscope can di spl ay the square
wave patterns of each vol tage pul se. From the wi dth
of the output vol tage pul ses, the PCM cal cul ates
engi ne speed. The wi dth of the pul ses represent the
amount of ti me the output vol tage stays hi gh before
swi tchi ng back to l ow. The peri od of ti me the sensor
output vol tage stays hi gh before swi tchi ng back to
l ow i s referred to as pul se wi dth. The faster the
FIRING ORDER2.4L
Fig. 1 Timing Reference Notches
engi ne i s operati ng, the smal l er the pul se wi dth on
the osci l l oscope.
By counti ng the pul ses and referenci ng the pul se
from the 60 degree si gnature notch, the PCM cal cu-
l ates crankshaft angl e (posi ti on). I n each group of
ti mi ng reference notches, the fi rst notch represents
69 degrees before top dead center (BTDC). The sec-
ond notch represents 49 degrees BTDC. The thi rd
notch represents 29 degrees. The l ast notch i n each
set represents 9 degrees before top dead center
(TDC).
The ti mi ng reference notches are machi ned to a
uni form wi dth representi ng 13.6 degrees of crank-
shaft rotati on. From the vol tage pul se wi dth the
PCM tel l s the di fference between the ti mi ng refer-
ence notches and the 60 degree si gnature notch. The
60 degree si gnature notch produces a l onger pul se
wi dth than the smal l er ti mi ng reference notches. I f
the camshaft posi ti on sensor i nput swi tches from
hi gh to l ow when the 60 degree si gnature notch
passes under the crankshaft posi ti on sensor, the
PCM knows cyl i nder number one i s the next cyl i nder
at TDC.
The crankshaft posi ti on sensor mounts to the
engi ne bl ock behi nd the generator, near the oi l fi l ter
(Fi g. 8).
The PCM determi nes fuel i njecti on synchroni zati on
and cyl i nder i denti fi cati on from i nputs provi ded by
the camshaft posi ti on sensor and crankshaft posi ti on
sensor. From the two i nputs, the PCM determi nes
crankshaft posi ti on.
The camshaft posi ti on sensor attaches to the rear
of the cyl i nder head (Fi g. 2). A target magnet
attaches to the rear of the camshaft and i ndexes to
the correct posi ti on (Fi g. 3). The target magnet has
four di fferent pol es arranged i n an asymmetri cal pat-
tern. As the target magnet rotates, the camshaft
posi ti on sensor senses the change i n pol ari ty (Fi g. 4).
The sensor output swi tch swi tches from hi gh (5.0
vol ts) to l ow (0.30 vol ts) as the target magnet rotates.
When the north pol e of the target magnet passes
under the sensor, the output swi tches hi gh. The sen-
sor output swi tches l ow when the south pol e of the
target magnet passes underneath.
INTAKE AIR TEMPERATURE SENSOR2. 4L
The i ntake ai r temperature sensor measures the
temperature of the ai r as i t enters the engi ne. The
sensor suppl i es one of the i nputs the PCM uses to
determi ne i njector pul se wi dth and spark advance.
The i ntake ai r temperature sensor threads i nto the
i ntake mani fol d (Fi g. 5).
Fig. 3 Target Magnet
Fig. 4 Target Magnet Polarity
SPARK PLUG CABLE SERVICE2. 4L
The cabl es i nsul ate the spark pl ugs and covers the
top of the spark pl ug tube (Fi g. 6). To remove the
cabl es, l i ghtl y grasp the top of the cabl e. Rotate the
i nsul ator 90 and pul l strai ght up. To repl ace the
cabl es, di sconnect the cabl e from the i gni ti on coi l .
Ensure the #1 and #4 cables run under the #2
and #3 ignition coil towers. Keep #4 cable away
from the oil fill cap.
SPARK PLUG SERVICE
When repl aci ng the spark pl ugs and spark pl ug
cabl es, route the cabl es correctl y and secure them i n
the appropri ate retai ners. Fai l ure to route the cabl es
properl y can cause the radi o to reproduce i gni ti on
noi se, cross i gni ti on of the spark pl ugs or short cir-
cuit the cables to ground.
Never Wire Brush Spark Plugs. The spark pl ug
i nsul ator ti p i s harder than the bri stl es of wi re
brushes. Bri stl es of wi re brushes can l eave a conduc-
ti ve, metal l i c fi l m on the i nsul ator whi ch coul d l ead
to conducti ve deposi ts. Conducti ve deposi ts can cause
spark pl ug fai l ure and engi ne mi sfi re. Use a jewel ers
fi l e to remove deposi ts from the el ectrode gap or use
a spark pl ug cl eani ng machi ne to cl ean spark pl ugs.
REMOVAL
Al ways remove cabl es by graspi ng at the boot,
rotati ng the boot 1/2 turn, and pul l i ng strai ght back
i n a steady moti on.
(1) Pri or to removi ng the spark pl ug, spray com-
pressed ai r around the spark pl ug hol e and the area
around the spark pl ug.
(2) Remove the spark pl ug usi ng a qual i ty socket
wi th a foam i nsert.
(3) I nspect the spark pl ug condi ti on. Refer to
Spark Pl ug Condi ti on i n thi s secti on.
INSTALLATION
(1) To avoi d cross threadi ng, start the spark pl ug
i nto the cyl i nder head by hand.
(2) Ti ghten spark pl ugs to 28 Nm (20 ft. l bs.)
torque.
(3) I nstal l spark pl ug cabl es over spark pl ugs. A
cl i ck wi l l be heard and fel t when the cabl e properl y
attaches to the spark pl ug.
IGNITION COIL2. 4L
REMOVAL
REMOVAL
(1) Remove spark pl ug cabl es from coi l (Fi g. 7).
Al ways twi st the coi l boots to break the seal wi th the
coi l and pul l strai ght back on the boot.
(2) Remove i gni ti on coi l el ectri cal connector.
(3) Remove i gni ti on coi l mounti ng bol ts, throttl e
cabl e bracket or cl i p.
(4) Remove i gni ti on coi l .
INSTALLATION
(1) Reverse the above procedure for i nstal l ati on.
Ti ghten mounti ng screws to 12 Nm (105 i n. l bs.)
torque.
(2) Transfer i gni ti on cabl es to new coi l pack. The
coi l pack towers and cabl es are numbered wi th cyl i n-
der i denti fi cati on.
Fig. 5 Intake Air Temperature Sensor
Fig. 6 Spark Plug Cables
engi ne bl ock behi nd the generator, just behi nd the oi l
fi l ter (Fi g. 8).
REMOVAL
(1) Rai se and support vehi cl e.
(2) Di sconnect el ectri cal connector from crankshaft
posi ti on sensor.
(3) Remove sensor mounti ng screw.
(4) Pul l crankshaft posi ti on sensor strai ght out.
INSTALLATION
NOTE: If the removed sensor is to be reinstalled,
clean off the old spacer on the sensor face. A NEW
SPACER must be attached to the sensor face before
installation. If the sensor is being replaced, confirm
that the paper spacer is attached to the face of the
new sensor.
(1) I nstal l sensor and push sensor down unti l con-
tact i s made. Whi l e hol di ng the sensor i n thi s posi -
ti on, and i nstal l and ti ghten the retai ni ng bol t to 11.9
Nm (105 i n. l bs.) torque.
The camshaft posi ti on sensor i s mounted to the
rear of the cyl i nder head (Fi g. 9).
REMOVAL
(1) Di sconnect the fi l tered ai r tube from the throt-
tl e body and ai r cl eaner housi ng. Di sconnect the ai r
tube from the oi l separator hose. Remove fi l tered ai r
tube.
(2) Remove the ai r cl eaner i nl et tube.
(3) Di sconnect engi ne harness connector from cam-
shaft posi ti on sensor.
(4) Remove camshaft posi ti on sensor mounti ng
screws. Remove sensor.
(5) Loosen screw attachi ng target magnet to rear
of camshaft (Fi g. 10).
INSTALLATION
The target magnet has l ocati ng dowel s that fi t i nto
off-set machi ned l ocati ng hol es i n end of the cam-
shaft (Fi g. 11).
Fig. 7 Ignition Coil Removal Fig. 8 Crankshaft Position Sensor
(1) I nstal l target magnet i n end of camshaft.
Ti ghten mounti ng screw to 5.65 Nm (50 i n. l bs.)
torque.
(2) I nstal l a new O-ri ng on sensor.
(3) I nstal l camshaft posi ti on sensor. Ti ghten sensor
mounti ng screws to 9.6 Nm (85 i n. l bs.) torque.
(4) Attach engi ne harness connector to camshaft
posi ti on sensor.
(5) I nstal l ai r cl eaner i nl et tube and fi l tered ai r
tube.
SENSOR2. 4/3. 3/3. 8L
REMOVAL
(1) Di sconnect el ectri cal connector from MAP sen-
sor (Fi g. 12).
(2) Remove two screws hol di ng sensor to the
i ntake mani fol d.
INSTALLATION
Refer to Group 14, Fuel I njecti on Secti on, for
Removal /I nstal l ati on.
ENGINE COOLANT TEMPERATURE SENSOR2. 4L
The cool ant sensor threads i nto the top of the ther-
mostat housi ng (Fi g. 13). New sensors have seal ant
appl i ed to the threads.
WARNING: HOT, PRESSURIZED COOLANT CAN
CAUSE INJURY BY SCALDING. COOLING SYSTEM
MUST BE PARTIALLY DRAINED BEFORE REMOV-
ING THE COOLANT TEMPERATURE SENSOR.
REFER TO GROUP 7- COOLING.
Fig. 11 Target Magnet Installation
Fig. 12 Map Absolute Pressure Sensor
Fig. 13 Engine Coolant Temperature Sensor2.4L
REMOVAL
(1) Wi th the engi ne col d, drai n cool ant unti l l evel
drops bel ow cyl i nder head. Refer to Group 7, Cool i ng
System.
(2) Di sconnect cool ant sensor el ectri cal connector.
(3) Remove cool ant sensor.
INSTALLATION
(1) I nstal l cool ant sensor. Ti ghten sensor to 7 Nm
(60 i n. l bs.) torque.
(2) Attach el ectri cal connector to sensor.
(3) Fi l l cool i ng system. Refer to Group 7, Cool i ng
System.
KNOCK SENSOR2. 4L
i nder bl ock i n front of the starter (Fi g. 14).
REMOVAL
(1) Di sconnect el ectri cal connector from knock sen-
sor.
(2) Use a crow foot socket to remove the knock
sensors.
INSTALLATION
(1) I nstal l knock sensor. Ti ghten knock sensor to
10 Nm (7 ft. l bs.) torque. Over or under tighten-
ing effects knock sensor performance, possibly
causing improper spark control.
(2) Attach el ectri cal connector to knock sensor.
i ntake mani fol d pl enum (Fi g. 15).
REMOVAL
(1) Remove el ectri cal connector from sensor.
(2) Remove sensor.
INSTALLATION
(1) I nstal l sensor. Ti ghten sensor to 28 Nm (20 ft.
l bs.) torque.
Fig. 14 Knock Sensor
SPECIFICATIONS
IGNITION COIL
SPARK PLUG
TORQUE
DESCRI PTI ON . . . . . . . . . . . . . . . . . . . . . .TORQUE
2.4L Target Magnet Screw . . . . . . .3 Nm (30 i n. l bs.)
2.4L Camshaft Posi ti on Sensoe Screw . .9 Nm (80 i n.
l bs.)
I gni ti on Swi tch . . . . . . . . . . . . . . .2 Nm (17 i n. l bs.)
Spark Pl ugs . . . . . . . . . . . . . . . . .28 Nm (60 i n. l bs.)
SPARK PLUG CABLE RESISTANCE2. 4L
Coil Manufacture
Primary Resistance at 21C-27C
(70F-80F)
Secondary Resistance at 21C-
27C (70F-80F)
Weastec (Steel Towers) 0.45 to 0.65 Ohms 7,000 to 15,800 Ohms
Coil Polarity
Engine Spark Plug Gap Thread Size
2.4L RC12YC5 0.048 TO 0.053 14mm (3/4 in.) reach
CABLE Maximum
Resistance
#1 & #4 4.2K ohms
#2 & #3 3.2K ohms
3.0L ENGINE
INDEX
page page
FIRING ORDER3.0L . . . . . . . . . . . . . . . . . . . . 23
SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.0L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
IGNITION COIL3.OL . . . . . . . . . . . . . . . . . . . . 24
SENSOR3.0L . . . . . . . . . . . . . . . . . . . . . . . . 24
SPARK PLUG SERVICE . . . . . . . . . . . . . . . . . . . 24
DISTRIBUTOR3.0L . . . . . . . . . . . . . . . . . . . . . 26
DISTRIBUTOR CAP . . . . . . . . . . . . . . . . . . . . . . 26
DISTRIBUTOR ROTOR3.0L . . . . . . . . . . . . . . . 27
SPECIFICATIONS
SPARK PLUG CABLE RESISTANCE3.0L . . . . . 27
SPARK PLUG . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
FIRING ORDER3. 0L
The MAP sensor reacts to absol ute pressure i n the
i ntake mani fol d and provi des an i nput vol tage to the
Powertrai n Control Modul e (PCM). As engi ne l oad
changes, mani fol d pressure vari es. The changes i n
engi ne l oad cause the MAP sensors resi stance to
change. The change i n MAP sensor resi stance resul ts
i n a di fferent i nput vol tage to the PCM.
The i nput vol tage l evel suppl i es the PCM wi th
i nformati on rel ati ng to ambi ent barometri c pressure
duri ng engi ne start-up (cranki ng) and engi ne l oad
whi l e i ts operati ng. Based on MAP sensor vol tage
and i nputs from other sensors, the PCM adjusts
spark advance and the ai r-fuel mi xture.
The 3.0L engi ne i s equi pped wi th a camshaft
dri ven mechani cal di stri butor, contai ni ng a shaft
dri ven di stri butor rotor. The di stri butor i s al so
equi pped wi th an i nternal camshaft posi ti on (fuel
sync) sensor (Fi g. 1). Thi s sensor provi des fuel i njec-
ti on synchroni zati on and cyl i nder i denti fi cati on to
the PCM.
The camshaft posi ti on sensor contai ns a hal l effect
devi ce cal l l ed a sync si gnal generator. Thi s sync si g-
nal generator detects a rotati ng pul se ri ng (shutter)
on the di stri butor shaft. The pul se ri ng rotates 180
through the sync si gnal generator. I ts si gnal i s used
i n conjuncti on wi th the crankshaft posi ti on sensor to
di fferenti ate between fuel i njecti on and spark events.
I t i s al so used to synchroni ze the fuel i njectors wi th
thei r respecti ve cyl i nders.
When the l eadi ng edge of the shutter enters the
sync si gnal generator, the i nterrupti on of magneti c
fi el d causes the vol tage to swi tch hi gh. Thi s causes a
sync si gnal of approxi matel y 5 vol ts.
When the trai l i ng edge of the shutter l eaves the
sync si gnal generator, the change of magneti c fi el d
causes the sync si gnal vol tage to swi tch l ow to 0
vol ts.
Si nce the shutter rotates at hal f crankshaft speed,
i t may take 1 engi ne revol uti on duri ng cranki ng for
the PCM to determi ne the posi ti on of pi ston number
6.
SPARK PLUG WIRE ROUTING3.0L ENGINE
SPARK PLUG SERVICE
When repl aci ng the spark pl ugs and spark pl ug
cabl es, route the cabl es correctl y and secure them i n
the appropri ate retai ners. Fai l ure to route the cabl es
properl y can cause the radi o to reproduce i gni ti on
noi se, cross i gni ti on of the spark pl ugs or short cir-
cuit the cables to ground.
Never Wire Brush Spark Plugs. The spark pl ug
i nsul ator ti p i s harder than the bri stl es of wi re
brushes. Bri stl es of wi re brushes can l eave a conduc-
ti ve, metal l i c fi l m on the i nsul ator whi ch coul d l ead
to conducti ve deposi ts. Conducti ve deposi ts can cause
spark pl ug fai l ure and engi ne mi sfi re. Use a jewel ers
fi l e to remove deposi ts from the el ectrode gap or use
a spark pl ug cl eani ng machi ne to cl ean spark pl ugs.
REMOVAL
Al ways remove cabl es by graspi ng at the boot,
rotati ng the boot 1/2 turn, and pul l i ng strai ght back
i n a steady moti on.
(1) Pri or to removi ng the spark pl ug, spray com-
pressed ai r around the spark pl ug hol e and the area
around the spark pl ug.
(2) Remove the spark pl ug usi ng a qual i ty socket
wi th a foam i nsert.
(3) I nspect the spark pl ug condi ti on. Refer to
Spark Pl ug Condi ti on i n thi s secti on.
INSTALLATION
(1) To avoi d cross threadi ng, start the spark pl ug
i nto the cyl i nder head by hand.
(2) Ti ghten spark pl ugs to 28 Nm (20 ft. l bs.)
torque.
(3) I nstal l spark pl ug cabl es over spark pl ugs. A
cl i ck wi l l be heard and fel t when the cabl e properl y
attaches to the spark pl ug.
IGNITION COIL3. OL
The i gni ti on coi l i s l ocated at the back of the
i ntake mani fol d (Fi g. 2).
REMOVAL
(2) Di sconnect i gni ti on cabl e from coi l .
(3) Di sconnect wi ri ng harness connector from coi l .
(4) Remove coi l mounti ng screws.
INSTALLATION
(1) Loosel y i nstal l i gni ti on coi l on i ntake mani fol d.
Ti ghten the i ntake mani fol d fastener to 13 Nm (115
i n. l bs.) torque. Ti ghten i gni ti on coi l bracket fasten-
ers to 10 Nm (96 i n. l bs.) torque.
(2) Connect the wi ri ng harness connector.
(3) Connect the coi l to di stri butor i gni ti on cabl e.
(4) I nstal l the ai r cl eaner assembl y. Ti ghten the
ai r cl eaner fasteners to 25 Nm (225 i n. l bs.) torque.
SENSOR3. 0L
REMOVAL
(1) Remove vacuum hose and mounti ng screws
from mani fol d absol ute pressure (MAP) sensor (Fi g.
3).
(2) Di sconnect el ectri cal connector from sensor.
Remove sensor.
Fig. 1 Camshaft Position Sensor3.0L Engine
Fig. 2 Ignition Coil3.0L Engine
INSTALLATION
The sensor i s i nstal l ed next to the thermostat
housi ng (Fi g. 3).
REMOVAL
System.
INSTALLATION
System.
REMOVAL
(2) Di sconnect crankshaft posi ti on sensor el ectri cal
connector from the wi ri ng harness connector (Fi g. 4).
(3) Remove crankshaft posi ti on sensor retai ni ng
bol t.
(4) Pul l crankshaft posi ti on sensor strai ght up out
of the transaxl e housi ng.
INSTALLATION
new sensor (Fig. 5).
(1) I nstal l sensor i n transaxl e and push sensor
down unti l contact i s made wi th the dri ve pl ate.
Whi l e hol di ng the sensor i n thi s posi ti on, and i nstal l
and ti ghten the retai ni ng bol t to 11.9 Nm (105 i n.
l bs.) torque.
(3) Connect crankshaft posi ti on sensor el ectri cal
connector to the wi ri ng harness connector.
Fig. 3 Manifold Absolute Pressure Sensor
Fig. 4 Crankshaft Position Sensor Connector
Fig. 5 Crankshaft Position Sensor and Spacer
DISTRIBUTOR3. 0L
REMOVAL
(1) Di sconnect di stri butor connector from di stri bu-
tor (Fi g. 6).
(2) Loosen di stri butor cap retai ni ng screws.
(3) Li ft cap of off di stri butor.
(4) Rotate engi ne crankshaft unti l the di stri butor
rotor poi nts to the i ntake mani fol d pl enum. Scri be a
mark on the pl enum i n l i ne wi th the rotor. The scri be
l i ne i ndi cates where to posi ti on the rotor when rei n-
stal l i ng the di stri butor.
(5) Remove di stri butor hol d down nut (Fi g. 7).
(6) Careful l y l i ft the di stri butor from the engi ne.
INSTALLATION
(1) Posi ti on di stri butor i n engi ne. Make certai n
that the O-ri ng i s properl y seated on di stri butor. I f
O-ri ng i s cracked or ni cked repl ace wi th new one.
(2) Careful l y engage di stri butor dri ve wi th gear on
camshaft. When the di stri butor i s i nstal l ed properl y,
the rotor wi l l be i n l i ne wi th previ ousl y scri be l i ne on
ai r i ntake pl enum. If engine was cranked while
distributor was removed, it will be necessary to
establish proper relationship between the dis-
tributor shaft and Number 1 piston position as
follows:
(a) Rotate the crankshaft unti l number one pi s-
ton i s at top of compressi on stroke.
(b) Rotate rotor to number one rotor termi nal
(Fi g. 8).
(c) Lower the di stri butor i nto the openi ng,
engagi ng di stri butor dri ve wi th dri ve on camshaft.
Wi th di stri butor ful l y seated on engi ne, rotor
shoul d be under the number 1 termi nal .
(3) I nstal l the di stri butor cap. Ensure sure al l hi gh
tensi on wi res are fi rml y i n the cap towers.
(4) I nstal l hol d-down nut and ti ghten (Fi g. 7).
(5) Connect di stri butor el ectri cal connector to di s-
tri butor (Fi g. 6).
DISTRIBUTOR CAP
Remove the di stri butor cap and i nspect the i nsi de
for fl ashover, cracki ng of carbon button, l ack of
spri ng tensi on on carbon button, cracki ng of cap, and
burned, worn termi nal s (Fi g. 9). Al so check for bro-
ken di stri butor cap towers. I f any of these condi ti ons
are present the di stri butor cap and/or cabl es shoul d
be repl aced.
Fig. 6 Distributor Electrical Connector3.0L Engine
Fig. 7 Distributor Hold-Down
Fig. 8 Distributor Cap Terminal Routing, View from
Top of Cap
When repl aci ng the di stri butor cap, transfer spark
pl ug wi res from the ori gi nal cap to the new cap one
at a ti me. Ensure that each wi re i s i nstal l ed i nto the
tower of the new cap that corresponds to i ts tower
posi ti on i n the ori gi nal cap. Ful l y seat the wi res i nto
the towers. I f necessary, refer to the engi ne fi ri ng
order di agram.
Li ght scal i ng of the termi nal s can be cl eaned wi th
a sharp kni fe. I f the termi nal s are heavi l y scal ed,
repl ace the di stri butor cap.
A cap that i s greasy, di rty or has a powder-l i ke
substance on the i nsi de shoul d be cl eaned wi th a
sol uti on of warm water and a mi l d detergent. Scrub
the cap wi th a soft brush. Thoroughl y ri nse the cap
and dry i t wi th a cl ean soft cl oth.
DISTRIBUTOR ROTOR3. 0L
Repl ace the rotor i f i t i s cracked, the ti p i s exces-
si vel y burned or heavi l y scal ed (Fi g. 10).
SPECIFICATIONS
SPARK PLUG
TORQUE
Di stri butor Hol d Down . . . . . . . .14 Nm (124 i n. l bs.)
I gni ti on Coi l Bracket . . . . . . . . . .10 Nm (96 i n. l bs.)
Spark Pl ugs . . . . . . . . . . . . . . . . .28 Nm (60 i n. l bs.)
SPARK PLUG CABLE RESISTANCE3. 0L
Fig. 9 Distributor Cap InspectionTypical
Fig. 10 Rotor InspectionTypical
Engine Spark Plug Gap Thread Size
3.0L RN11YC4 0.039 TO 0.044 14mm (3/4 in.) reach
CABLE Maximum
Resistance
#1 14.0K ohms
#2 10.4K ohms
#3 14.9K ohms
#4 11.5K ohms
#5 17.5K ohms
#6 10.3K ohms
Coil Lead 11.1K ohms
3.3/3.8L ENGINE
INDEX
page page
FIRING ORDER3.3/3.8L . . . . . . . . . . . . . . . . . 28
IGNITION COIL . . . . . . . . . . . . . . . . . . . . . . . . . 30
KNOCK SENSOR3.3/3.8L . . . . . . . . . . . . . . . . 32
SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
SPARK PLUG CABLE SERVICE3.3/3.8L
ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
SPARK PLUG SERVICE3.3/3.8L ENGINES . . . 29
SPECIFICATIONS
IGNITION COIL . . . . . . . . . . . . . . . . . . . . . . . . . 33
SPARK PLUG CABLE RESISTANCE3.3/3.8L . . 34
SPARK PLUG . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
FIRING ORDER3. 3/3. 8L
The fi ri ng order for 3.3L and 3.8L engi nes i s 1-2-3-
4-5-6.
SPARK PLUG CABLE SERVICE3. 3/3. 8L ENGINES
WARNING: The ignition cables should not be
removed while the engine is hot. This could cause
sever injury/burns and can cause damage to the
ignition cables.
The spark pl ug boot heat shi el d needs to be
i nstal l ed correctl y on the boot before bei ng i nstal l ed
on the engi ne (Fi g. 1). I f i t i s not i nstal l ed correctl y
engi ne mi sfi re woul d occur.
Do not use pl i ers to pul l the boot/heat shi el d
assembl y from the spark pl ugs. Thi s wi l l damage the
shi el d assembl y.
Spark pl ug boot heat shi el ds must be repl aced i f
they are bent or damaged. I t i s extremel y i mportant
the shi el d i s rei nstal l ed correctl y as shown. The bot-
tom of the spark pl ug heat shi el d must make contact
wi th the spark pl ug socket hex.
Firing Order3.3/3.8L
Fig. 1 Spark Plug Boot/Heat Shield Orientation
CAUTION: Never coat the inside of spark plug
boots with silicone grease. Some types of silicone
grease can damage the ignition cable conductor.
SPARK PLUG CABLES #3 AND #5
REMOVAL
(1) Remove the resonator.
(2) Grasp the spark pl ug boot/heat shi el d as cl ose
as possi bl e to the spark pl ug. Twist the boot
slightly to break its seal with the plug and pull
straight back. Do not use pliers, pull on the
ignition cable, or pull the spark plug boot at an
angle. Thi s coul d damage the spark pl ug i nsul ator,
termi nal , or the cabl e i nsul ati on. Wi pe spark pl ug
i nsul ator cl ean wi th a dry cl oth before i nstal l ati on.
(3) Remove the cabl e from the retai ni ng bracket.
Make sure that they are al so detached from the rear
retai ni ng cl i p mounted on the rear of the i ntake
mani fol d.
INSTALLATION
(1) When i nstal l i ng the spark pl ug cabl es, make
sure the coi l and spark pl ug i nsul ator and termi nal s
are ful l y seated. A click sound should be heard or
terminal engagement is felt when the terminals
are properly attached.
(2) I nstal l the cabl e i nto the retai ni ng bracket.
Make sure that they are al so attached to the rear
mani fol d.
(3) I nstal l the resonator.
SPARK PLUG CABLE #1
REMOVAL
(1) Remove the accessory dri ve bel t, refer to Group
7, Cool i ng.
(2) Remove the four bol ts from the upper hal f of
the generator bracket.
(3) Push the Generator rearward.
(4) Grasp the spark pl ug boot/shi el d assembl y as
cl ose as possi bl e to the spark pl ug. Twist the boot
slightly to break its seal with the plug and pull
straight back. Do not use pliers, pull on the
ignition cable, or pull the spark plug boot at an
angle. Thi s coul d damage the spark pl ug i nsul ator,
termi nal , or the cabl e i nsul ati on. Wi pe spark pl ug
i nsul ator cl ean wi th a dry cl oth before i nstal l ati on.
(5) Remove the cabl e from the retai ni ng bracket.
INSTALLATION
sure the coi l and spark pl ug i nsul ator and termi nal s
terminal engagement is felt when the terminals
are properly attached.
(2) Rotate Generator back i nto pl ace.
(3) I nstal l upper Generator bracket wi th the four
bol ts.
(4) I nstal l the accessory dri ve bel t, refer to Group
7, Cool i ng.
SPARK PLUG SERVICE3. 3/3. 8L ENGINES
WARNING: The ignition cables should not be
removed while the engine is hot. This could cause
server injury/burns and can cause damage to the
ignition cables.
Use extreme care when removi ng and i nstal l i ng
the spark pl ug cabl es.
The spark pl ug boot heat shi el d needs to be
i nstal l ed correctl y on the boot before bei ng i nstal l ed
on the engi ne (Fi g. 1). I f i t i s not i nstal l ed correctl y
engi ne mi sfi re woul d occur.
Do not use pl i ers to pul l the boot/heat shi el d
assembl y from the spark pl ugs. Thi s wi l l damage the
shi el d assembl y.
SPARK PLUG #3 AND #5
REMOVAL
(1) Remove the resonator.
(2) Remove i ntake strut to cyl i nder head bol t at
cyl i nder head.
(3) Loosen bol t for i ntake strut at i ntake.
(4) Swi ng strut away.
cl ose as possi bl e to the spark pl ug. Twist the boot/
shield assembly slightly to break the seal with
the plug and pull straight out. Do not use pli-
ers, pull on the ignition cable, or pull the spark
plug boot at an angle. Thi s coul d damage the
spark pl ug i nsul ator, termi nal , heat shi el d or the
i nsul ati on. Wi pe spark pl ug i nsul ator cl ean wi th a
dry cl oth before i nstal l ati on.
(6) Remove spark pl ug
INSTALLATION
(1) I nstal l spark pl ug and ti ghten to 28 Nm (20 ft.
l bs.).
sure spark pl ug i nsul ator and termi nal s are ful l y
seated. A click sound should be heard or felt
when the terminals are properly attached.
(3) I nstal l the cabl e i nto the retai ni ng bracket.
Make sure that they are al so attached to the rear
mani fol d.
(4) Swi ng strut back i nto pl ace.
(5) I nstal l i ntake strut bol t to cyl i nder head at cyl -
i nder head.
(6) Ti ghten bol t to i ntake strut at i ntake.
(7) Ti ghten bol t at cyl i nder head.
(8) I nstal l the resonator.
SPARK PLUG #1
REMOVAL
(1) Remove the accessory dri ve bel t, refer to Group
7, Cool i ng.
(2) Remove the 4 bol ts from the upper hal f of the
generator bracket.
(3) Push the Generator rearward.
cl ose as possi bl e to the spark pl ug. Twist the boot/
shield assembly slightly to break its seal with
the plug and pull straight out. Do not use pli-
ers, pull on the ignition cable, or pull the spark
plug boot at an angle. Thi s coul d damage the
spark pl ug i nsul ator, termi nal , or the i nsul ati on.
Wi pe spark pl ug i nsul ator cl ean wi th a dry cl oth
before i nstal l ati on.
(5) Remove spark pl ug
INSTALLATION
(1) I nstal l spark pl ug and ti ghten to 28 Nm (20 ft.
l bs.).
sure the coi l or spark pl ug i nsul ator and termi nal s
felt when the terminals are properly attached.
(3) Pul l Generator back i nto pl ace.
(4) I nstal l upper Generator bracket wi th the 4
bol ts.
(5) I nstal l the accessory dri ve bel t, refer to Group
7, Cool i ng.
IGNITION COIL
REMOVAL
(1) Remove spark pl ug cabl es from coi l (Fi g. 2).
Al ways twi st the spark pl ug boots to break the seal
wi th the pl ug and pul l strai ght back on the boot.
(2) Remove i gni ti on coi l el ectri cal connector.
(3) Remove i gni ti on coi l mounti ng screws.
INSTALLATION
Ti ghten mounti ng screws to 12 Nm (105 i n. l bs.)
torque.
(2) Transfer spark pl ug cabl es to new coi l pack.
The coi l pack towers and cabl es are numbered wi th
the cyl i nder i denti fi cati on.
REMOVAL
(2) Di sconnect crankshaft posi ti on sensor el ectri cal
(3) Remove crankshaft posi ti on sensor retai ni ng
bol t.
(4) Pul l crankshaft posi ti on sensor strai ght up out
of the transaxl e housi ng.
INSTALLATION
new sensor (Fig. 4).
(1) I nstal l sensor i n transaxl e and push sensor
down unti l contact i s made wi th the dri ve pl ate.
Fig. 2 Ignition Coil Removal
Fig. 3 Crankshaft Position Sensor Connector
Whi l e hol di ng the sensor i n thi s posi ti on, and i nstal l
and ti ghten the retai ni ng bol t to 11.9 Nm (105 i n.
l bs.) torque.
(3) Connect crankshaft posi ti on sensor el ectri cal
connector to the wi ri ng harness connector.
REMOVAL
(1) Di sconnect camshaft posi ti on sensor el ectri cal
(2) Remove bol t hol di ng sensor (Fi g. 6). There is a
hole in the bracket for tool access to the sensor
bolt.
(3) Rotate sensor away from bl ock (Fi g. 7).
(4) Pul l sensor up out of the chai n case cover. Do
not pull on the sensor lead. There i s an O-ri ng on
the sensor case. The O-ri ng may make removal di ffi -
cul t. A l i ght tap to top of sensor pri or to removal may
reduce force needed for removal .
INSTALLATION
If the removed sensor is reinstalled, clean off
the old spacer on the sensor face. A NEW
SPACER must be attached to the face before
installation. I nspect O-ri ng for damage, repl ace i f
necessary. I f the sensor i s bei ng repl aced, confi rm
that the paper spacer i s attached to the face and O-
ri ng i s posi ti oned i n groove of the new sensor (Fi g. 8).
(1) Appl y a coupl e drops of cl ean engi ne oi l to the
O-ri ng pri or to i nstal l ati on.
(2) I nstal l sensor i n the chai n case cover and
rotate i nto posi ti on.
(3) Push sensor down unti l contact i s made wi th
the camshaft gear. Whi l e hol di ng the sensor i n thi s
posi ti on, i nstal l and ti ghten the retai ni ng bol t 14
(4) Connect camshaft posi ti on sensor el ectri cal
connector to harness connector.
Fig. 4 Crankshaft Position Sensor and Spacer
Fig. 6 Camshaft Sensor Bolt Removal/Installation
Fig. 7 Camshaft Sensor Removal/Installation
REMOVAL
sor.
(2) Remove 2 screws hol di ng sensor to i ntake man-
i fol d (Fi g. 9).
(3) Remove sensor from mani fol d.
INSTALLATION
Reverse the above procedure for i nstal l ati on.
The Engi ne Cool ant Temperature (ECT) sensor i s
l ocated bel ow the i gni ti on coi l (Fi g. 10).
REMOVAL
(1) Drai n cool i ng system unti l cool ant l evel i s
bel ow sensor. Refer to Group 7, Cool i ng System.
(2) Remove el ectri cal connector from coi l (Fi g. 11).
(3) Remove coi l mounti ng screws.
(4) Rotate coi l away from engi ne cool ant tempera-
ture sensor.
(5) Di sconnect el ectri cal connector from engi ne
cool ant temperature sensor.
(6) Remove sensor from engi ne.
INSTALLATION
(1) Ti ghten the sensor to 7 Nm (60 i n. l bs.) torque.
(2) Connect el ectri cal connector to sensor.
System.
(4) I nstal l coi l . Ti ghten coi l mounti ng screws to 12
(5) Connect el ectri cal connector to coi l .
KNOCK SENSOR3. 3/3. 8L
i nder bl ock i n front of the starter (Fi g. 12).
Fig. 8 Camshaft Position Sensor and Spacer
Fig. 10 Engine Coolant Temperature Sensor
REMOVAL
(1) Di sconnect el ectri cal connector from knock sen-
sor.
(2) Use a crow foot socket to remove the knock
sensor.
INSTALLATION
(1) I nstal l knock sensor. Ti ghten knock sensor to
10 Nm (7 ft. l bs.) torque. Over or under tighten-
ing effects knock sensor performance, possibly
causing improper spark control.
(2) Attach el ectri cal connector to knock sensor.
SPECIFICATIONS
IGNITION COIL
Coil Manufacture
Primary Resistance at 21C-27C
(70F-80F)
Secondary Resistance at 21C-
27C (70F-80F)
Weastec (Aluminum Towers) 0.45 TO 0.65 Ohms 7,000 to 15,800 Ohms
Diamond Electric (Brass Towers) 0.45 TO 0.65 Ohms 7,000 to 15,800 Ohms
Coil Polarity
Coil Polarity
SPARK PLUG
* New Spark Pl ug Gap
TORQUE
3.3L Camshaft Posi ti on
Sensor Screw . . . . . . . . . . . . .12 Nm (105 i n. l bs.)
3.3L Engi ne Cool ant Sensor . . . . . .7 Nm (60 i n. l bs.)
3.3L Crankshaft Posi ti on
Sensor Screw . . . . . . . . . . . . .12 Nm (105 i n. l bs.)
3.3/3.8L I gni ti on Coi l . . . . . . . . .12 Nm (105 i n. l bs.)
Spark Pl ugs . . . . . . . . . . . . . . . . .28 Nm (20 ft. l bs.)
SPARK PLUG CABLE RESISTANCE3. 3/3. 8L
Engine Spark Plug Gap * Thread Size
3.3L RN14PMP5 0.048 TO 0.053 14mm (3/4 in.) reach
3.8L RN14PMP5 0.048 TO 0.053 14mm (3/4 in. ) reach
CABLE Maximum
Resistance
#1 18.5K ohms
#2 15.5K ohms
#3 20.4K ohms
#4 21.2K ohms
#5 27.7K ohms
#6 26.7K ohms
IGNITION SWITCH AND LOCK CYLINDER
INDEX
page page
IGNITION INTERLOCK . . . . . . . . . . . . . . . . . . . . 35
LOCK KEY CYLINDER . . . . . . . . . . . . . . . . . . . . 35
IGNITION INTERLOCK . . . . . . . . . . . . . . . . . . . . 38
IGNITION SWITCH . . . . . . . . . . . . . . . . . . . . . . . 35
LOCK CYLINDER HOUSING . . . . . . . . . . . . . . . 38
LOCK KEY CYLINDER . . . . . . . . . . . . . . . . . . . . 38
IGNITION INTERLOCK
Al l vehi cl es equi pped wi th automati c transaxl es
have an i nterl ock system. The system prevents shi ft-
i ng the vehi cl e out of Park unl ess the i gni ti on l ock
cyl i nder i s i n the Off, Run or Start posi ti on. I n addi -
ti on, the operator cannot rotate the key to the l ock
posi ti on unl ess the shi fter i s i n the park posi ti on. On
vehi cl es equi pped wi th fl oor shi ft refer to Group 21 -
Transaxl e for Automati c Transmi ssi on Shi fter/I gni -
ti on I nterl ock.
LOCK KEY CYLINDER
The l ock cyl i nder i s i nserted i n the end of the
housi ng opposi te the i gni ti on swi tch. The i gni ti on key
rotates the cyl i nder to 5 di fferent detents (Fi g. 1):
Accessory
Off (l ock)
Unl ock
On/Run
Start
IGNITION SWITCH
The i gni ti on swi tch attaches to the l ock cyl i nder
housi ng on the end opposi te the l ock cyl i nder (Fi g. 2).
For i gni ti on swi tch termi nal and ci rcui t i denti fi ca-
ti on, refer to Group 8W, Wi ri ng Di agrams.
Fig. 1 Ignition Lock Cylinder Detents
Fig. 2 Ignition SwitchViewed From Below Column
REMOVAL
(2) Remove steeri ng col umn cover retai ni ng screws
(Fi g. 3).
(3) Remove parki ng brake rel ease cabl e from han-
dl e (Fi g. 4).
(4) Remove screws hol di ng steeri ng col umn
shrouds (Fi g. 5) and remove l ower shroud.
(5) Pl ace key cyl i nder i n RUN posi ti on. Depress
l ock cyl i nder retai ni ng tab and remove key cyl i nder
(Fi g. 6).
(6) Remove i gni ti on swi tch mounti ng screw (Fi g. 7)
wi th a #10 Torx tamper proof bi t.
(7) Depress retai ni ng tab (Fi g. 3) or (Fi g. 8) and
gentl y pry i gni ti on swi tch from steeri ng col umn (Fi g.
9).
(8) Di sconnect el ectri cal connectors from i gni ti on
swi tch and remove swi tch (Fi g. 10).
Fig. 3 Steering Column Cover
Fig. 4 Parking Brake Release Cable
Fig. 5 Steering Column Shroud Screws
Fig. 6 Lock Cylinder Retaining Tab
INSTALLATION
(1) Ensure the i gni ti on swi tch i s i n the RUN posi -
ti on and the actuator shaft i n the l ock housi ng i s i n
the RUN posi ti on.
(2) I nstal l el ectri cal connectors to i gni ti on swi tch.
(3) Careful l y i nstal l the i gni ti on swi tch. The
swi tch wi l l snap over the retai ni ng tabs (Fi g. 11).
I nstal l mounti ng screw (Fi g. 7).
(4) I nstal l upper and l ower shrouds.
(5) I nstal l key cyl i nder (cyl i nder retai ni ng tab wi l l
depress onl y i n the RUN posi ti on).
(7) Check for proper operati on of i gni ti on swi tch
and key-i n warni ng swi tch.
Fig. 7 Ignition Switch Mounting Screw
Fig. 8 Ignition Switch Retaining Tab
Fig. 9 Removing Ignition Switch
Fig. 10 Ignition Switch Connectors
Fig. 11 Ignition Switch Installation
LOCK KEY CYLINDER
REMOVAL
(2) Remove steeri ng col umn cover retai ni ng screws
(Fi g. 3).
(3) Remove screws hol di ng steeri ng col umn
shrouds (Fi g. 5) and remove l ower shroud.
(4) Pl ace key cyl i nder i n RUN posi ti on. Depress
l ock cyl i nder retai ni ng tab and remove key cyl i nder
(Fi g. 6).
INSTALLATION
(1) I nstal l key i n l ock cyl i nder. Turn key to run
posi ti on (retai ni ng tab on l ock cyl i nder can be
depressed).
(2) The shaft at the end of the l ock cyl i nder al i gns
wi th the socket i n the end of the housi ng. To al i gn
the socket wi th the l ock cyl i nder, ensure the socket i s
i n the Run posi ti on (Fi g. 12).
(3) Al i gn the l ock cyl i nder wi th the grooves i n the
housi ng. Sl i de the l ock cyl i nder i nto the housi ng
unti l the tab sti cks through the openi ng i n the hous-
i ng.
(4) Turn the key to the Off posi ti on. Remove the
key.
(5) I nstal l l ower steeri ng col umn shroud.
(6) I nstal l steeri ng col umn cover.
IGNITION INTERLOCK
Refer to Group 21, Transaxl e for Shi fter/I gni ti on
I nterl ock Servi ce.
LOCK CYLINDER HOUSING
Refer to Steeri ng Col umn i n Group 19, Steeri ng,
for Lock Cyl i nder Housi ng Servi ce.
Fig. 12 Socket in Lock Cylinder Housing
INSTRUMENT PANEL AND SYSTEMS
CONTENTS
page page
GENERAL INFORMATION
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . 1
INSTRUMENT CLUSTER . . . . . . . . . . . . . . . . . . . 1
DIAGNOSTIC PROCEDURES . . . . . . . . . . . . . . . . 2
HEADLAMP SWITCH . . . . . . . . . . . . . . . . . . . . . 2
SELF DIAGNOSTIC TEST . . . . . . . . . . . . . . . . . . 2
TRACTION CONTROL SWITCH . . . . . . . . . . . . . 17
BODY CONTROL MODULE (BCM) . . . . . . . . . . 18
CONVENIENCE BIN - CUP HOLDER . . . . . . . . . 17
CONVENIENCE BIN LAMP . . . . . . . . . . . . . . . . 17
CONVENIENCE BIN TRACK . . . . . . . . . . . . . . . 18
GLOVE BOX LAMP AND SWITCH . . . . . . . . . . 19
GLOVE BOX LOCK STRIKER . . . . . . . . . . . . . . 20
GLOVE BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
HEADLAMP SWITCH LAMP(S) . . . . . . . . . . . . 21
HEADLAMP SWITCH . . . . . . . . . . . . . . . . . . . . 20
HVAC CONTROL LAMP . . . . . . . . . . . . . . . . . . 21
INSTRUMENT CLUSTER BACK PANEL . . . . . . 21
INSTRUMENT CLUSTER BEZEL . . . . . . . . . . . . 21
INSTRUMENT CLUSTER ELECTRONIC
ODOMETER AND TRANSMISSION RANGE
INDICATOR . . . . . . . . . . . . . . . . . . . . . . . . . . 19
INSTRUMENT CLUSTER LAMPS . . . . . . . . . . . 22
INSTRUMENT CLUSTER LENS - MECHANICAL
TRANSMISSION RANGE INDICATOR
(PRND21) . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
INSTRUMENT CLUSTER LENS . . . . . . . . . . . . . 22
INSTRUMENT CLUSTER PRINTED CIRCUIT
BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
INSTRUMENT CLUSTER SUBDIAL . . . . . . . . . . 23
INSTRUMENT CLUSTER SUBDIAL
MECHANICAL TRANSMISSION RANGE
INDICATOR . . . . . . . . . . . . . . . . . . . . . . . . . . 23
INSTRUMENT CLUSTER WITH ELECTRONIC
TRANSMISSION RANGE INDICATOR . . . . . . 23
INSTRUMENT CLUSTER WITH MECHANICAL
TRANSMISSION RANGE INDICATOR . . . . . . 24
INSTRUMENT PANEL LEFT END COVER . . . . . 27
INSTRUMENT PANEL LOUVERS . . . . . . . . . . . 27
INSTRUMENT PANEL RIGHT END COVER . . . . 29
INSTRUMENT PANEL TOP COVER . . . . . . . . . . 29
INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . 25
J UNCTION BLOCK . . . . . . . . . . . . . . . . . . . . . . 30
KNEE BLOCKER REINFORCEMENT . . . . . . . . . 30
LOWER CONSOLE . . . . . . . . . . . . . . . . . . . . . . 30
LOWER INSTRUMENT PANEL . . . . . . . . . . . . . 31
LOWER STEERING COLUMN COVER . . . . . . . . 31
MECHANICAL TRANSMISSION RANGE
INDICATOR . . . . . . . . . . . . . . . . . . . . . . . . . . 32
MESSAGE CENTER LAMP . . . . . . . . . . . . . . . . 32
MESSAGE CENTER . . . . . . . . . . . . . . . . . . . . . . 32
OUTLET (12 VOLT) BASE . . . . . . . . . . . . . . . . . 32
OVER STEERING COLUMN BEZEL . . . . . . . . . . 32
POWER MIRROR SWITCH LAMP . . . . . . . . . . 34
POWER MIRROR SWITCH . . . . . . . . . . . . . . . . 34
RADIO BEZEL AND HVAC CONTROL . . . . . . . . 34
REAR HEATER-A/C SWITCH LAMP . . . . . . . . . 35
REAR HEATER-A/C SWITCH . . . . . . . . . . . . . . . 35
TRACTION CONTROL SWITCH . . . . . . . . . . . . . 35
GENERAL INFORMATION
INTRODUCTION
The i nstrumentati on gauges on NS vehi cl es are
contai ned i n a subdi al assembl i es wi thi n the i nstru-
ment cl uster. The i ndi vi dual gauges are not servi ced
separatel y. I f one of the cl uster gauges becomes
faul ty the enti re subdi al woul d requi re repl acement
and al l gauges wi l l have to be cal i brated. Refer to the
proper Body Di agnosti c Procedure Manual for cal i -
brati on procedures.
INSTRUMENT CLUSTER
The mechani cal i nstrument cl uster wi th a tachom-
eter i s equi pped wi th a el ectroni c vacuum fl uorescent
transmi ssi on range i ndi cator (PRND3L), odometer,
and tri p odometer di spl ay.
The mechani cal i nstrument cl uster wi thout a
tachometer i s equi pped wi th a cabl e operated trans-
mi ssi on range i ndi cator (PRND21).
NS INSTRUMENT PANEL AND SYSTEMS 8E - 1
The i nstrument cl uster i s equi pped wi th the fol l ow-
i ng warni ng l amps.
Li ft Gate Ajar
Low Fuel Level
Low Wi ndshi el d Washer Fl ui d Level
Crui se
Battery Vol tage
Fasten Seat Bel t
Door Ajar
DIAGNOSTIC PROCEDURES
NS vehi cl e i nstrument cl usters are equi pped wi th a
sel f di agnosti c test feature to hel p i denti fy el ectroni c
probl ems. Pri or to any test, perform Sel f Di agnosti c
Test. The sel f di agnosti c system moni tors the CCD
bus messages. I f an el ectroni c probl em occurs, a
Di agnosti c Troubl e Code (DTC) wi l l be di spl ayed i n
the odometer wi ndow of the cl uster.
The fol l owi ng CCD bus messages are conti nuousl y
moni tored by the di agnosti c system:
Powertrai n Control Modul e
Transmi ssi on Control Modul e, i f equi pped
HEADLAMP SWITCH
Usi ng a Di gi tal Mul ti meter, equi pped wi th a di ode
test to perform the Headl amp Swi tch Test bel ow (Fi g.
1).
Swi tch posi ti on possi bi l i ti es are open (no conti nu-
i ty), conti nui ty, resi stance val ue i n ohms, or di ode
test. Use the val ues i n the thi rd col umn to determi ne
meter setti ng. I f Headl amp Swi tch i s not wi thi n spec-
i fi cati ons repl ace as necessary.
The Chrysl er Town and Country i s avai l abl e wi th
opti onal Automati c Headl amps. For di agnosi s, refer
to the proper Body Di agnosti c Procedures Manual .
SELF DIAGNOSTIC TEST
To acti vate sel f di agnosti c program:
(1) Wi th the i gni ti on swi tch i n the OFF posi ti on,
depress the TRI P and RESET buttons.
(2) Whi l e hol di ng the TRI P and RESET button
turn the i gni ti on swi tch to the ON posi ti on.
(3) Conti nue to hol d the TRI P and RESET buttons
unti l the word CODE appears i n the odometer wi n-
dows (about fi ve seconds) then rel ease the buttons. I f
a probl em exi sts, the system wi l l di spl ay Di agnosti c
Troubl e Codes (DTCs). I f no probl em exi sts, the code
999 (End Test) wi l l momentari l y appear.
DIM TEST
When CHEC-0 i s di spl ayed i n the odometer wi n-
dow, the cl usters vacuum fl uorescent (VF) di spl ays
wi l l di m down. I f the VF di spl ay bri ghtness does no
change, a probl em exi sts i n the cl uster.
Fig. 1 Headlamp Switch Test
8E - 2 INSTRUMENT PANEL AND SYSTEMS NS
CLUSTER CALIBRATION TABLE
Speedometer Calibration Point
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . .0 mph (0 Km/h)
2 . . . . . . . . . . . . . . . . . . . . . . . . . .20 mph (40 Km/h)
3 . . . . . . . . . . . . . . . . . . . . . . . . . .55 mph (80 Km/h)
4 . . . . . . . . . . . . . . . . . . . . . . . . .75 mph (120 Km/h)
Tachometer Calibration Point
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0 rpm
2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1000 rpm
3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3000 rpm
4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6000 rpm
Fuel Gauge Calibration Point
1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Empty (E)
2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1/8 Fi l l ed
3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1/4 Fi l l ed
4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ful l (F)
Temperature Gauge Calibration Point
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Col d (C)
2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Low Normal
3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hi gh Normal
4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hot (H)
CALIBRATION TEST
dow, each of the cl usters gauge poi nters wi l l move
sequenti al l y through each cal i brati on poi nt. The Cal -
i brati on Tabl e contai ns the proper cal i brati on poi nts
for each gauge. I f the gauge poi nters are not cal i -
brated, a probl em exi sts i n the cl uster. I f any gauge
i s out of cal i brati on i t wi l l have to be cal i brated usi ng
a scan tool (DRB I I I ). Refer to the proper Body Di ag-
nosti c Procedure Manual for cal i brati on procedures.
ODOMETER SEGMENT TEST
dow, each di gi t of the odometer wi l l i l l umi nate
sequenti al l y. I f a segment i n the odometer does not
i l l umi nate normal l y, a probl em exi sts i n the di spl ay.
ELECTRONIC TRANSMISSION RANGE
INDICATOR SEGMENT TEST
dow, each segment of the transmi ssi on range i ndi ca-
tor wi l l i l l umi nate sequenti al l y. I f a segment i n the
transmi ssi on range i ndi cator does not i l l umi nate nor-
mal l y, a probl em exi sts i n the di spl ay board.
CONDITIONS
Refer to the fol l owi ng tabl es:
Speedometer
Tachometer
Fuel Gauge
Temperature Gauge
Odometer
El ectroni c Transmi ssi on Range I ndi cator
(PRND3L)
Mechani cal Transmi ssi on Range I ndi cator
(PRND21)
for possi bl e/probl ems/causes and correcti ons.
INSTRUMENT CLUSTER DTC TABLE
DTC DESCRIPTION
110 Memory Fault in cluster
111 Calibration fault in cluster
905 No CCD bus messages from TCM
921 Odometer fault from BCM
940 No CCD bus messages from PCM
999 End of Codes
INSTRUMENT CLUSTER DIAGNOSIS
INSTRUMENT CLUSTER
INOPERATIVE-NO
RESPONSE
No CCD bus messages
from the Body Control
Module (BCM).
1. Use a scan tool to check the BCM. If OK, look for
another possible cause for cluster failure. If not OK,
refer to the proper Body Diagnostic Procedure Manual.
Spread terminal(s) on
wiring harness cluster
connector.
1. Remove cluster from instrument panel and check
wiring harness connector for spread terminal. If OK,
look for another possible cause for the cluster failure. If
not OK, repair connector.
Body Control Module
(BCM) is not receiving
proper input from the
ignition switch.
1. Use a scan tool to verify ignition switch status into
the BCM. If not OK, go to Step (2). If OK, look at
another possible cause of failure.
2. Check ignition switch function and wiring.
Internal cluster failure. 1. Replace main cluster pc board and use a scan tool
to calibrate cluster.
SPEEDOMETER DIAGNOSIS
NO POINTER
MOVEMENT
1. Internal cluster failure. 1. (a) Perform cluster self diagnostic test and check for
fault codes.
If speedometer pointer moves to calibration points
during test and fault codes 110 or 111 dont appear in
the odometer display then failure is not in the cluster.
Look for another possible cause of failure.
If the pointer doesnt move during test, go to Step
(b).
If fault code 110 is displayed in the odometer, go to
Step (b).
If fault code 111 is displayed in the odometer then go
to Step (f).
If fault codes 905, 920, or 940 are displayed in the
odometer display refer to the fault code chart to identify
which module is causing the fault and repair module.
(b) Replace main cluster pc board. Go to Step (c).
(c) Connect cluster into instrument panel wiring
harness. Place it back into the proper position in the
instrument panel. Put in the top two mounting screws to
hold the cluster in place. DO NOT COMPLETELY
INSTALL CLUSTER TO INSTRUMENT PANEL UNTIL
UNIT IS CALIBRATED AND TESTED. Go to Step (d).
(d) Use a scan tool to calibrate cluster and perform Self
Diagnostic Test. If OK, complete installation. If not OK,
go to Step (e).
(e) Replace subdial assembly and use a scan tool to
calibrate cluster. If not OK, look at another possible
cause for the speedometer failure.
(f) Use a scan tool to calibrate speedometer and
perform Self Diagnostic Test. If OK, stop. If not OK, go
to Step (b).
2. No speed CCD Bus
Message or Zero mph
CCD Speed Bus
Message.
2. (a) Check the Body Control Module (BCM) using a
scan tool. If OK, go to Step (b). If not OK, refer to the
BCM section of the service manual to repair the BCM.
(b) Check the Powertrain Control Module (PCM) using
a scan tool. If OK, go to Step (c). If not OK, refer to the
PCM section of the service manual to repair the PCM.
(c) Check the speed signal input into the PCM. The
speed signal originates from one of the following
sources:
A distance sensor for vehicles with 3 speed automatic
transmission. Check continuity from distance sensor to
PCM. If OK, replace distance sensor. If not OK, repair
wiring.
The Electronic Transmission Control Module (TCM)
for vehicles with the 4 speed electronic transmissions.
Check continuity from TCM to PCM. If OK, use a scan
tool to check TCM. Refer to the electronic TCM section
of the service manual to repair the TCM. If not OK,
repair wiring.
ERRATIC POINTER
MOVEMENT
1. Erratic Message from
another Module.
1. (a) Check the BCM using a scan tool If OK, go to
Step (b). If not OK, refer to the BCM section of the
service manual to repair the BCM.
(b) Check the PCM using a scan tool. If OK, go to Step
(c). If not OK, refer to the PCM section of the service
manual to repair the PCM.
(c) Check the speed signal input into the PCM. The
speed signal originates from one of the following
sources:
A distance sensor for vehicles with 3 speed automatic
transmission. Check continuity from distance sensor to
PCM. If OK, replace distance sensor. If not OK, repair
wiring.
The Electronic Transmission Control Module (TCM)
vehicles with the 4 speed electronic transmissions.
Check continuity from TCM to engine controller. If OK,
use a scan tool to check TCM. Refer to the electronic
section of the service manual to repair the TCM. If not
OK, repair wiring.
2. Internal Cluster Failure. 2. (a) Perform cluster self diagnostic test and check for
fault codes.
If the pointer moves during test but still appears
erratic and fault codes 110 or 111 dont appear in the
odometer display, then go to Step (b).
Step (e).
If fault code 111 appears in the odometer display go
to Step (d).
If fault codes 905, 920, or 940 are displayed in the
(b) Replace cluster subdial assembly. To Step (c).
Diagnostic Test. If OK, continue installation. If not OK,
go to Step (e).
Replace main cluster pc board and use a scan tool to
cause for the speedometer failure.
SPEEDOMETER
INACCURATE.
1. Speedometer Out of
Calibration.
1. (a) Perform Cluster Self Diagnostic Test.
If speedometer is accurate to the calibration points
then look for another possible cause of inaccuracy.
If speedometer is not accurate to the calibration
points, go to Step (b).
(b) Use a scan tool to calibrate speedometer.
2. Wrong Speedometer
Pinion Size For Tire Size.
2. (a) If vehicle has a 4 speed electronic transmission
go to Step (c). Otherwise go to Step (b).
(b) Check if correct speedometer pinion is being used
with tires on vehicle. Refer to transmission section of
manual for test and repair procedure.
If the incorrect pinion is in transmission then replace
with correct pinion.
If the correct pinion is in the transmission calibrate
speedometer using a scan tool to correct for the
inaccuracy.
(c) use a scan tool to check the TCM to see if the
correct tire size has been programmed into the TCM.
If the incorrect tire size was selected, select the
proper tire size.
If the correct tire size was selected, calibrate
speedometer to correct for the inaccuracy.
3. Bad Speed Sensor. 3. Refer to the proper section of the service manual for
test and repair procedure.
TACHOMETER DIAGNOSIS
NO POINTER
MOVEMENT
1. Internal Cluster Failure. 1. (a) Perform Cluster Self Diagnostic Test and check
for fault codes.
If tachometer pointer moves to calibration points
during test and fault codes 110 or 111 dont appear in
the odometer display then failure is not in the cluster.
Look for another possible cause of failure.
(b).
Step (b).
to Step (f).
If fault codes 920 or 940 are displayed in the
which module is causing the fault an repair module.
(d) use a scan tool to calibrate cluster and perform Self
go to Step (e).
cause for the tachometer failure.
(f) Use a scan tool to calibrate tachometer and perform
Self Diagnostic Test. If OK, stop. If not OK, go to Step
(b).
2. No rpm CCD Bus
Message or Zero rpm
CCD Bus Message from
Engine Controller.
2. Check the PCM using a scan tool. Refer to the PCM
section of the manual to properly diagnose and repair.
ERRATIC POINTER
MOVEMENT.
1. Bad CCD Bus
Message from Engine
Controller.
1. Check the PCM using a scan tool. Refer to the PCM
section of the manual to properly diagnose and repair.
for fault codes.
odometer display, go to Step (b).
Step (e).
to Step (d).
If fault codes 920 or 940 are displayed in the
(b) Replace cluster subdial assembly. Go to Step (c).
hold the cluster in place DO NOT COMPLETELY
go to Step (e).
(e) Replace main cluster pc board and use a scan tool
to calibrate cluster. If not OK, look at another possible
cause for the tachometer failure.
TACHOMETER
INACCURATE.
1. Tachometer out of
calibration.
1. Calibrate tachometer using a scan tool.
FUEL GAUGE DIAGNOSIS
NO POINTER
MOVEMENT.
1. Internal cluster failure. 1. (a) Perform Cluster Self Diagnostic Test and check
for fault codes.
If fuel gauge pointer moves to calibration points during
test and fault codes 110 or 111 dont appear in the
odometer display then failure is not in the cluster. Look
for another possible cause of failure.
If the pointer doesnt move during test, go to Step (b).
Step (b).
to Step (f).
If fault code 920 is displayed in the odometer refer to
the fault code chart to identify which module is causing
the fault and repair module.
go to Step (e).
cause for the fuel gauge failure.
(f) Use a scan tool to calibrate fuel gauge and perform
Self Diagnostic Test. If OK, stop. If not OK, go to Step
(b).
2. No CCD Fuel Message
or Empty CCD Bus
Message from Body
Controller.
2. (a) Check the BCM using a scan tool. If OK, go to
manual to properly diagnose and repair.
(b) Refer to the Fuel section of the service manual for
the fuel level sending unit test procedure. Test unit and
repair as instructed.
ERRATIC POINTER
MOVEMENT.
1. Bad CCD Fuel
Message from the Body
Controller.
1. (a) Use a scan tool to check the BCM. If OK, go to
service manual to properly diagnose and repair.
(b) Refer to the Fuel section of the service manual for
the fuel level sending unit test procedure. Test unit. If
OK, look for another possible cause for fuel gauge
failure. If not OK, repair sending unit.
for fault codes.
Step (e).
If fault code 111 appears in the odometer display to
Step (d).
If fault code 920 is displayed in the odometer refer to
the fault code chart to identify which module is causing
the fault and repair module.
go to Step (e).
cause for the fuel gauge failure.
FUEL GAUGE
INACCURATE.
1. Fuel Gauge Out of
Calibration.
1. (a) Perform Cluster Self Diagnostic Test. If pointer is
accurate to the calibration points look for another
possible cause of failure. If pointer is inaccurate to the
calibration points, to Step (b).
(b) Use a scan tool to calibrate fuel gauge.
2. Fuel Level Sending
Unit is Out of Calibration.
2. (a) Refer to the Fuel section of the service manual
for test and repair procedure.

TEMPERATURE GAUGE DIAGNOSIS
NO POINTER
MOVEMENT
for fault codes.
If temperature gauge pointer moves to calibration
points during test and fault codes 110 or 111 dont
appear in the odometer display then failure is not in the
cluster. Look for another possible cause of failure.
(b).
Step (b).
to Step (f).
If fault codes 920 or 940 are displayed refer to the
fault code chart to identify which module is causing the
fault and repair module.
(d) use a scan tool to calibrate cluster and perform Self
go to Step (e).
cause for the temperature gauge failure.
(f) Use a scan tool to calibrate temperature gauge and
perform Self Diagnostic Test. If OK, stop. If not OK, go
to Step (b).
2. No CCD Temperature
Message or Cold CCD
Bus Message from the
Body Control Module.
2. (a) Check BCM fault codes using a scan tool. If
there are not faults, go to Step (b). If there are faults,
refer to the BCM section of the manual to properly
diagnose and repair.
(b) Check PCM fault codes using a scan tool. If there
are no faults, go to Step (c). If there are faults, refer to
the PCM section of the manual to properly diagnose
and repair.
(c) Refer to the coolant sensor section of the service
manual for the coolant sensor test procedure. Repair
sensor as needed.
ERRATIC POINTER
MOVEMENT.
1. Bad CCD Bus
Message from the Body
Control Module.
1. (a) Check BCM fault codes using a scan tool. If
there are no faults, go to Step (b). If there are faults,
refer to the BCM section of the manual to properly
diagnose and repair.
(b) Check PCM fault codes using a scan tool. If there
are no faults, go to Step (c). If there are faults, refer to
the PCM section of the manual to properly diagnose
and repair.
(c) Refer to the coolant sensor section of the service
manual for the coolant sensor test procedure. Repair
sensor as needed.
for fault codes.
Step (e).
to Step (d).
If fault code 920 or 940 is displayed refer to the fault
code chart to identify which mode is causing the fault
and repair module.
instrument panel. DO NOT COMPLETELY INSTALL
CLUSTER TO INSTRUMENT PANEL UNTIL UNIT IS
CALIBRATED AND TESTED. Go to Step (d).
go Step (e).
cause for the temperature gauge failure.
TEMPERATURE GAUGE
INACCURATE.
1. Temperature Gauge
Out of Calibration.
1. (a) Perform Cluster Self-Diagnostic Test.
If pointer is accurate to the calibration points look for
another possible cause of failure.
If pointer is inaccurate to the calibration points, go
the Step (b).
(b) Use a scan tool to calibrate temperature gauge.
2. Coolant Sensor Out of
Calibration.
2. Refer to the Cooling section of the service manual
for test and repair procedure.
ODOMETER DIAGNOSIS
CONDITION
POSSIBLE
CAUSES
CORRECTION
NO DISPLAY 1. No CCD
Odometer Bus
Message from Body
Control Module.
1. Use a scan tool to check the BCM. Refer to the BCM section of
the manual to properly diagnose and repair.
2. Internal Cluster
Failure.
2. (a) Perform Cluster Self Diagnostic Test and check for fault
codes.
If odometer passes the dim test and segment check and
fault codes 110 or 111 dont appear in the odometer display
then failure is not in the cluster. Look for another possible
cause of failure.
If odometer doesnt work go to Step (b).
If fault code 110 is displayed in the odometer, go to Step (b).
If fault code 920 or 921 is displayed use a scan tool to check
BCM.
(b) Remove cluster from instrument panel and verify that
odometer assembly is properly connected to main pc board. If
OK, go to Step (c). If not OK, reconnect odometer assembly to
main pc board.
(c) Replace odometer assembly. Go to Step (d).
(d) Connect cluster into instrument panel wiring harness.
Place it back into the proper position in the instrument panel.
DO NOT COMPLETELY INSTALL CLUSTER TO INSTRUMENT
PANEL UNTIL UNIT IS TESTED. Go to Step (e).
(e) Perform Self Diagnostic Test. If OK, continue installation. If
not OK, go to Step (f).
(f) Replace main cluster pc board and use a scan tool to
calibrate cluster. If not OK, look at another possible cause for
the odometer failure.
CONDITION
POSSIBLE
CAUSES
CORRECTION
ERRATIC DISPLAY 1. Internal Cluster
Failure.
codes.
If odometer passes the dim test and segment check and fault
codes 110 or 111 dont appear in the odometer displayed then
failure is not in the cluster. Look for another possible cause of
failure.
If odometer doesnt work go to Step (b).
If fault code 110 is displayed in the odometer, go to Step (b).
If fault code 920 or 921 is displayed use a scan tool to check
BCM.
(b) Remove cluster from instrument panel and verify that odometer
assembly is properly connected to main pc board. If OK, go to
Step (c). If not OK, reconnect odometer assembly to main pc
board.
(c) Replace odometer assembly. Go to Step (d).
(d) Connect cluster into instrument panel wiring harness. Place it
back into the proper position in the instrument panel. DO NOT
COMPLETELY INSTALL CLUSTER TO INSTRUMENT PANEL
UNTIL UNIT TESTED. Go to Step (e).
(e) Perform Self diagnostic Test. If OK, continue installation. If not
OK, go to Step (f).
(f) Replace main cluster pc board and use a scan tool to calibrate
cluster. If not OK, look at another possible cause for the odometer
failure.
2. Bad CCD Bus
Message from Body
Controller Module.
2. Use a scan tool to check the BCM. Refer to the BCM section of
the manual to properly diagnose and repair.
ODOMETER WONT
GO INTO TRIP
MODE.
1. Trip Switch
Doesnt Work.
1. Use a scan tool to perform trip switch activation test. If OK, look
for another possible cause of failure. If not OK, replace odometer
assembly.
TRIP ODOMETER
WONT RESET.
1. Reset Switch
Doesnt Work.
1. Use a scan tool to perform reset switch activation test. If OK,
look for another possible cause of failure. If not OK, replace
odometer assembly.
ELECTRONIC GEAR INDICATOR DISPLAY DIAGNOSIS
CONDITION
POSSIBLE
CAUSES
CORRECTION
NO DISPLAY 1. Internal Cluster
Failure.
codes.
If PRND3L passes the dim test and segment check and fault
codes 110 or 111 dont appear in the odometer display then
failure is not in the cluster. Look for another possible cause of
failure.
If PRND3L doesnt work go to Step (b).
If fault code 110 is displayed in the odometer, go to Step (b)
If fault code 905 is displayed use a scan tool to check
electronic TCM.
(b) Remove cluster from instrument panel and verify that
PRND3L assembly is properly connected to main pc board. If
OK, go to Step (c). If not OK, reconnect PRND3L assembly to
main pc board.
(c) Replace PRND3L assembly. Go to Step (d).
(d) Connect cluster into instrument panel wiring harness.
Place it back into the proper position in the instrument panel.
DO NOT COMPLETELY INSTALL CLUSTER TO INSTRUMENT
PANEL UNTIL UNIT IS TESTED. Go to Step (e).
(e) Perform Self Diagnostic Test. If OK, continue installation. If
not OK, go to Step (f).
(f) Replace main cluster pc board and use a scan tool to
calibrate cluster. If not OK, look at another possible cause for
the PRND3L failure.
CONDITION
POSSIBLE
CAUSES
CORRECTION
ERRATIC DISPLAY 1. Internal Cluster
Failure.
codes.
If PRND3L passes the dim test and segment check and fault
codes 110 or 111 dont appear in the odometer display then failure
is not in the cluster. Look for another possible cause of failure.
If PRND3L doesnt work go to Step (b).
If fault code 110 is displayed in the odometer, go to Step (f).
If fault code 111 is displayed in the odometer display then use a
scan tool to calibrate cluster.
If fault code 905 is displayed use a scan tool to check electronic
TCM.
(b) Remove cluster from instrument panel and verify that odometer
assembly is properly connected to main pc board. If OK, go to
Step (c). If not OK, reconnect PRND3L assembly to main pc board.
(c) Replace PRND3L assembly. Go to Step (d).
(d) Connect cluster into instrument panel wiring harness. Place it
back into the proper position in the instrument panel. DO NOT
COMPLETELY INSTALL CLUSTER TO INSTRUMENT PANEL
UNTIL UNIT IS TESTED. Go to Step (e).
(e) Perform Self Diagnostic Test. If OK, continue installation. If not
OK, go to Step (f).
(f) Replace main cluster pc board and use a scan tool to calibrate
cluster. If not OK, look at another possible cause for the PRND3L
failure.
2. Bad CCD Bus
Message from the
Electronic
Transmission
Control Module
(TCM).
2. Use a scan tool to check the electronic TCM. Refer to the
electronic TCM section of the manual to properly diagnose and
repair.
ALL SEGMENTS
ARE ON
1. No CCD bus
message from the
electronic
Transmission
Control Module
(TCM).
1. (a) Perform Cluster Self Diagnostic test. If PRND3L passes test
go to Step (b). If PRND3L fails test go to Step (c).
(b) Check electronic TCM using a scan tool. Refer to the electronic
TCM section of the manual to properly diagnose and repair.
(c) Replace PRND3L assembly. Connect cluster into instrument
panel wiring harness. Place it back into the proper position in the
instrument panel. DO NOT COMPLETELY INSTALL CLUSTER TO
INSTRUMENT PANEL UNTIL UNIT IS TESTED. Go to Step (d).
(d) Perform Self Diagnostic Test. If OK, continue installation. If not
OK, go to Step (e).
(e) Replace main cluster pc board and use a scan tool to calibrate
cluster. If not OK, look at another possible cause for the PRND3L
failure.
TRACTION CONTROL SWITCH
(1) Remove over steeri ng col umn bezel . Refer to
Over Steeri ng Col umn Bezel . Removal procedures.
(2) Usi ng an ohmmeter check for conti nui ty read-
i ng between pi ns. Refer to Swi tch Conti nui ty Tabl e.
CONVENIENCE BIN - CUP HOLDER
REMOVAL
(1) Pul l the conveni ence bi n open (Fi g. 3).
(2) Push l ock tab at rear center downward.
(3) Pul l the conveni ence bi n - cup hol der from
track i n i nstrument panel .
(4) Remove conveni ence bi n - cup hol der.
INSTALLATION
CONVENIENCE BIN LAMP
I f the l amp i s not used refer to (Fi g. 4).
REMOVAL
(1) Pul l out and remove the conveni ence bi n - cup
hol der. Refer to Conveni ence Bi n - Cup Hol der
removal i n thi s secti on.
MECHANICAL TRANSMISSION RANGE INDICATOR (PRND21) DIAGNOSIS
INDICATOR DOES NOT
SHOW PROPER GEAR
OR NO INDICATION.
Mis-adjusted. 1. (a) Verify transmission shift system correctly
adjusted.
(b) Verify correct routing and attachment of PRNDL
cable and guide tube.
(c) Re-adjust PRNDL indicator in Neutral using adjuster
wheel below steering column.
INDICATOR DOES NOT
FOLLOW GEAR SHIFT
LEVER.
Not attached. 1. (a) Verify indicator cable connected to shift lever pin
in the groove.
(b) Verify indicator clip secure and attached to steering
column/transmission shift cable bracket and clip not
broken. If broken, replace clip on indicator.
INDICATOR DOES NOT
MAKE FULL TRAVEL (P
< > 1).
1. Cable dislodged from
its path on the indicator
base.
1. Verify correct attachment of indicator cable to shift
lever pin (under hoop of trans. shift cable) and clip onto
steering column/shift cable bracket.
2. Incorrect attachment of
cable to shift lever pin.
2. Verify indicator travel by pulling on cable gently over
full travel range. If still problem, remove cluster and
lens to access indicator base and confirm cable path
per attached sketch.
Fig. 2 Traction Control Switch Connector
SWITCH CONTINUITY TABLE
SWITCH POSITION CONTINUITY BETWEEN
ACTUATED PINS 1 AND 3
ILLUMINATION PINS 2 AND 3
Fig. 3 Convenience Bin Cup Holder
(2) I nsert the tri m sti ck (speci al tool #C-4755)
between access cover and radi o bezel , above conve-
ni ence bi n - cup hol der.
(3) Careful l y pry the access cover from the i nstru-
ment panel (Fi g. 5).
(4) Separate the access cover from the vehi cl e.
(5) Usi ng needl e-nose pl i ers, careful l y squeeze the
verti cal metal l egs of the l amp hood.
(6) Li ft the l amp hood upward from the cup hol der
tray.
(7) Careful l y pul l the l amp and wi ri ng rearward
from the i nstrument panel (Fi g. 6).
(8) Pul l the l amp hood from the l amp socket.
(9) Pul l bul b from socket.
INSTALLATION
For i nstal l ati on, for reverse the above procedures.
CONVENIENCE BIN TRACK
REMOVAL
(1) Remove the conveni ence bi n - cup hol der. Refer
to Conveni ence Bi n - Cup Hol der Removal and
I nstal l ati on procedure i n thi s secti on.
(2) Remove the screw access cover from the bottom
of the radi o bezel (Fi g. 5).
(3) Remove the center bezel .
(4) Remove the conveni ence bi n track attachi ng
screws and pul l the conveni ence bi n track rearward
to di sengage the rear gui de studs from i nstrument
panel (Fi g. 7).
(5) Di sengage the cl i p hol di ng conveni ence bi n
l amp to track.
(6) Remove the conveni ence bi n track.
INSTALLATION
BODY CONTROL MODULE (BCM)
REMOVAL
(1) Di sconnect battery negati ve cabl e.
(2) Remove l ower steeri ng col umn cover and knee
bl ocker rei nforcement.
Fig. 4 Unused Convenience Bin Lamp Socket
Location
Fig. 5 Convenience Bin Access Cover
Fig. 6 Convenience Bin Lamp Bulb
Fig. 7 Convenience Bin Track
(3) Di sconnect two wi re connectors from bottom of
Body Control Modul e (BCM)
(4) Remove bol ts hol di ng Juncti on Bl ock to dash
panel mounti ng bracket (Fi g. 8).
(5) Remove Juncti on Bl ock from mounti ng bracket.
(6) Remove screws hol di ng Body Control Modul e to
Juncti on Bl ock.
(7) Sl i de Body Control Modul e downward to di sen-
gage gui de studs on Juncti on Bl ock from channel s on
BCM mounti ng bracket.
(8) Remove Body Control Modul e from Juncti on
Bl ock.
INSTALLATION
INSTRUMENT CLUSTER LENS - MECHANICAL
TRANSMISSION RANGE INDICATOR (PRND21)
REMOVAL
(1) Remove the i nstrument cl uster and di sconnect
the range i ndi cator cabl e at both attachi ng poi nts.
Refer to I nstrument Cl uster wi th Mechani cal Trans-
mi ssi on Range I ndi cator Reval and I nstal l ati on pro-
cedures.
(2) Remove the screws hol di ng the cl uster l ens to
the rear shel l from around peri meter of l ens.
(3) Remove the l ens from the cl uster, gui de the
shi ft i ndi cator cabl e through cl uster shel l .
(4) Remove the screws hol di ng the shi ft i ndi cator
to the l ens.
INSTALLATION
(1) I nstal l the shi ft i ndi cator and screws to cl uster
l ens.
(2) Posi ti on the l ens on cl uster and careful l y gui de
the shi ft i ndi cator cabl e and gui de through cl uster
openi ng.
(3) I nstal l the cl uster l ens and screws to the rear
shel l around peri meter of l ens.
(4) I nstal l the i nstrument cl uster.
INSTRUMENT CLUSTER ELECTRONIC ODOMETER
AND TRANSMISSION RANGE INDICATOR
REMOVAL
(1) Remove i nstrument cl uster.
(2) Remove cl uster l ens.
(3) Di sconnect wi re connector from odometer and
transmi ssi on range i ndi cator.
(4) Remove screws hol di ng odometer and transmi s-
si on range i ndi cator to cl uster shel l .
(5) Remove odometer and transmi ssi on range i ndi -
cator from cl uster.
INSTALLATION
(1) I nstal l odometer and transmi ssi on range i ndi -
cator and attach to cl uster shel l .
(2) Connect wi re connector i nto odometer and
transmi ssi on range i ndi cator.
(3) I nstal l cl uster l ens.
(4) I nstal l i nstrument cl uster.
GLOVE BOX
REMOVAL (FIG. 4)
(1) Open gl ove box (Fi g. 9).
(2) Di sengage cl i p hol di ng checkstraps to gl ove box
door.
(3) Pi vot gl ove box downward and di sengage hi nge
hooks from i nstrument panel .
(4) Remove gl ove box.
INSTALLATION
(1) Pl ace gl ove box i n posi ti on.
(2) Engage hi nge hooks i nto i nstrument panel and
pi vot gl ove box upward.
(3) Engage cl i p to hol d checkstraps to gl ove box
door.
(4) Cl ose gl ove box door.
GLOVE BOX LAMP AND SWITCH
REMOVAL
(1) Open gl ove box door (Fi g. 10).
(2) Usi ng a tri m sti ck, l i ghtl y pry gl ove box l amp/
swi tch from i nstrument panel .
(3) Di sengage wi re connector from gl ove box l amp
and swi tch.
Fig. 8 Body Control Module Location
(4) Remove gl ove box l amp and swi tch.
(5) Remove l amp (Fi g. 11).
INSTALLATION
GLOVE BOX LOCK STRIKER
REMOVAL
door.
(3) Remove screws hol di ng l ock stri ker to i nstru-
ment panel .
(4) Remove gl ove box l ock stri ker.
INSTALLATION
HEADLAMP SWITCH
REMOVAL
(1) Remove i nstrument cl uster bezel (Fi g. 13).
(2) Remove screws hol di ng the headl amp swi tch
bezel to cl uster bezel .
(3) Di sconnect the wi re connectors from the head-
l amp swi tch and wi re connector from the power mi r-
ror swi tch.
(4) Remove headl amp swi tch bezel from cl uster
bezel .
INSTALLATION
Fig. 9 Glove Box
Fig. 10 Glove Box Lamp and Switch
Fig. 11 Glove Box Lamp
Fig. 12 Glove Box Lock Striker
Fig. 13 Headlamp Switch
HEADLAMP SWITCH LAMP(S)
REMOVAL
(1) Remove i nstrument cl uster bezel .
(2) Di sconnect wi re connectors.
(3) Remove headl amp swi tch bezel from i nstru-
ment cl uster bezel .
(4) Rotate bul b socket countercl ockwi se one quar-
ter turn (Fi g. 14).
(5) Pul l bul b socket from headl amp swi tch.
INSTALLATION
HVAC CONTROL LAMP
REMOVAL
(1) Remove radi o bezel and HVAC Control (Fi g.
15).
(2) Remove rear cover from HVAC control .
ter turn.
(4) Pul l bul b socket from HVAC.
INSTALLATION
INSTRUMENT CLUSTER BACK PANEL
REMOVAL
(2) Remove screws hol di ng back panel to i nstru-
ment cl uster (Fi g. 16).
(3) Remove back panel .
INSTALLATION
INSTRUMENT CLUSTER BEZEL
REMOVAL
(1) Remove steeri ng col umn cover.
(2) Remove over steeri ng col umn bezel (Fi g. 17).
(3) Remove l eft end cover.
(4) Remove screw at l eft end of cl uster bezel and
headl amp swi tch.
Fig. 14 Headlamp Switch Lamp
Fig. 15 HVAC Control Lamps
Fig. 16 Instrument Cluster Back Panel
Fig. 17 Instrument Cluster Bezel
(5) Remove screws hol di ng cl uster bezel to i nstru-
ment panel from each si de of steeri ng col umn.
(6) Di sconnect cl i p hol di ng cl uster bezel to i nstru-
ment panel from above ri ght vent l ouver.
(7) Separate cl uster bezel from i nstrument panel .
(8) Di sconnect wi re connectors from back of the
bezel .
INSTALLATION
(1) Connect wi re connectors i nto back of the bezel .
(2) Pl ace cl uster bezel i n posi ti on on i nstrument
panel . Use care not to pl ace hands on l ouvers.
(3) Connect cl i ps to hol d cl uster bezel to i nstru-
ment panel . Use care not to add pressure on the A/C
l ouvers to seat the cl uster bezel cl i ps.
(4) I nstal l screws to hol d cl uster bezel to i nstru-
ment panel on each si de of steeri ng col umn.
(5) I nstal l screw at l eft end of cl uster bezel and
headl amp swi tch.
(6) I nstal l l eft end cover.
(7) I nstal l over steeri ng col umn bezel .
(8) I nstal l l ower steeri ng col umn cover.
INSTRUMENT CLUSTER LAMPS
REMOVAL
(1) Remove the i nstrument cl uster. Refer to I nstru-
ment Cl uster Removal procedure.
(2) Locate the l amp (Fi g. 18).
(3) Remove the l amps from cl uster wi th a 1/4 turn
twi st.
INSTALLATION
For i nstal l ati on, reverse the procedures.
INSTRUMENT CLUSTER LENS
REMOVAL
(1) Remove the i nstrument cl uster.
(2) Remove the screws hol di ng the l ens to the
i nstrument cl uster (Fi g. 19).
(3) Remove the l ens from cl uster.
INSTALLATION
For i nstal l ati on, reverse the procedures.
Fig. 18 Cluster Lamp Location
Fig. 19 Instrument Cluster Lens
INSTRUMENT CLUSTER PRINTED CIRCUIT BOARD
REMOVAL
(2) Remove the i nstrument cl uster back panel .
(3) Di sconnect the el ectroni c cl uster wi re connector
from the pri nted ci rcui t board (Fi g. 20).
(4) Remove the screws hol di ng wi re connector
i nsul ator to the i nstrument cl uster shel l and the
pri nted ci rcui t board.
(5) Remove the screws hol di ng pri nted ci rcui t
board to the cl uster shel l .
(6) Remove the pri nted ci rcui t board from the cl us-
ter.
INSTALLATION
After i nstal l i ng the pri nt ci rcui t board i t wi l l have to
be cal i brated usi ng a scan tool (DRB I I I ). Refer to the
NOTE: Speedometer and/or Tachometer will not
operate properly until all gauges have been cali-
brated
REMOVAL
(2) Remove the cl uster l ens.
(3) Di sconnect the temperature/fuel gauge and the
tachometer termi nal s from the connectors i n cl uster
by pul l i ng the subdi al strai ght away from the cl uster
(Fi g. 21).
(4) Remove the subdi al from the cl uster.
INSTALLATION
INSTRUMENT CLUSTER SUBDIAL MECHANICAL
REMOVAL
(2) Remove screws hol di ng cl uster l ens to the rear
shel l from around peri meter of l ens.
(3) Remove l ens from cl uster, gui de shi ft i ndi cator
cabl e through cl uster shel l .
(4) Remove gauge subdi al from cl uster.
INSTALLATION
(1) Posi ti on gauge subdi al on cl uster.
(2) Posi ti on l ens on cl uster, gui de shi ft i ndi cator
cabl e through cl uster shel l .
(3) I nstal l cl uster l ens and screws to the rear shel l
around peri meter of l ens.
INSTRUMENT CLUSTER WITH ELECTRONIC
REMOVAL
(2) Remove screws hol di ng i nstrument cl uster to
i nstrument panel .
(3) Rotate top of cl uster outward.
(4) Remove i nstrument cl uster from i nstrument
panel .
(5) Di sconnect wi re connector from back of i nstru-
ment cl uster.
INSTALLATION
(1) Pl ace i nstrument cl uster i n i nstrument panel ,
bottom fi rst.
Fig. 20 Instrument Cluster Printed Circuit Board
Fig. 21 Instrument Cluster Subdial
(2) Connect wi re connector i nto back of i nstrument
cl uster.
(3) Posi ti on i nstrument cl uster i n i nstrument
panel .
(4) I nstal l i nstrument cl uster mounti ng screws to
i nstrument panel .
(5) I nstal l i nstrument cl uster bezel .
INSTRUMENT CLUSTER WITH MECHANICAL
REMOVAL
(1) Remove the l ower steeri ng col umn cover.
(2) Remove the metal knee bl ocker panel .
(3) Di sconnect the transmi ssi on range i ndi cator
cabl e end from shi ft l ever by fl exi ng the HOOP on
the transmi ssi on shi ft cabl e rearward and sl i p the
i ndi cator cabl e l oop off the l ever pi n (Fi g. 23).
(4) Di sconnect the cl i p hol di ng the i ndi cator cabl e
to the steeri ng col umn/transmi ssi on shi ft cabl e
bracket.
(5) Remove the i nstrument cl uster bezel .
(6) Rotate top of the cl uster rearward.
(7) Di sconnect the wi re connector from back of the
i nstrument cl uster.
(8) Remove the i nstrument cl uster careful l y whi l e
gui di ng the range i ndi cator cabl e and gui de tube
through the openi ng to avoi d any damage (Fi g. 24).
INSTALLATION
(1) Veri fy the free travel of the range i ndi cator
cabl e from P to 1 by gentl y pul l i ng on the cabl e and
rel axi ng the cabl e. DO NOT SNAP THE CABLE
ONCE I T I S PULLED.
(2) Posi ti on the i nstrument cl uster i n i nstrument
panel and route the i ndi cator cabl e and gui de tube
through the openi ng i n the i nstrument panel . Posi -
ti on the cl uster by l eadi ng the bottom i n fi rst, con-
nect the wi re connector, and rotate upward.
(3) I nstal l the screws to hol d the i nstrument cl us-
ter to the i nstrument panel .
(4) I nstal l the i nstrument cl uster bezel .
(5) Connect the cl i p to hol d the i ndi cator cabl e to
steeri ng col umn/transmi ssi on shi ft cabl e bracket. The
i ndi cator cabl e and gui de tube shoul d BOW towards
the passenger si de of the vehi cl e (Fi g. 25).
(6) Connect i ndi cator cabl e l oop end to shi ft l ever
by fl exi ng the hoop on the transmi ssi on shi ft cabl e
rearward, then sl i p the i ndi cator cabl e l oop over the
shi ft l ever pi n and i nto the groove.
(7) Assumi ng the transmi ssi on shi ft system i s
properl y adjusted, pl ace the shi ft l ever i n neutral N
posi ti on.
NOTE: The parking brake should have been
engaged for safety purposes.
Fig. 22 Instrument Panel Electronic Transmission
Range Indicator
Fig. 23 Range Indicator
Fig. 24 Removing and Installing Cluster
(8) Usi ng the i ndi cator adjuster thumbwheel on
the i ndi cator cl i p bel ow the steeri ng col umn. Rotate
the i ndi cator thumbwheel to posi ti on the i ndi cator
cal i brati on arrow to the center of the N sl ot on the
i nstrument cl uster mask.
(9) After the i ndi cator has been properl y adjusted,
move the shi ft l ever through each gear posi ti on to
veri fy the appropri ate gear posi ti on has been sel ected
and the sl ot i s ful l y covered by the i ndi cator. The l eft
edge of the i ndi cator wi l l just peek at the l eft edge of
the P sl ot i n Park.
(10) I f the i ndi cator i s not coveri ng each of the
sel ected gear posi ti ons when sel ected, pl ace the shi ft
l ever back i nto neutral N and readjust the i ndi cator.
Repeat the process unti l each gear i s covered when
sel ected.
(11) I nstal l the metal knee bl ocker panel .
(12) I nstal l the l ower steeri ng col umn cover.
INSTRUMENT PANEL
The i nstrument panel i s removed as a uni t. The
steeri ng col umn and wi ri ng harnesses are assembl ed
i nto the panel before i nstal l ati on. Servi ce procedures
for i nteri or tri m not rel ated to the i nstrument panel
can be found i n Group 23, Body.
REMOVAL
(1) Di sconnect the battery, negati ve cabl e fi rst.
(2) Remove the l ower consol e.
(3) Remove the screw hol di ng the l ower heat duct
to the i nstrument panel support (Fi g. 26).
(4) Di sconnect the heat duct from the vehi cl e.
(5) Remove the bol ts hol di ng the l ower supports to
the i nstrument panel frame (Fi g. 27).
the fl oor pan.
(7) Remove the ri ght and l eft end covers.
(8) Di sconnect the wi re connectors from the Pas-
senger Ai rbag Modul e.
(9) Remove the front door si l l tri m covers.
(10) Remove the A-pi l l ar tri m covers.
(11) Remove the gl ove box.
(12) Di sconnect the antenna l ead connector from
behi nd the gl ove box.
(14) Remove the knee bl ocker panel .
(15) Di sconnect the l ower two, forty pi n wi re har-
ness connectors, from the mai n Juncti on Bl ock near
l eft cowl si de panel (Fi g. 28).
(16) Di sconnect the i nstrument panel wi re harness
connector from the bottom of Body Control Modul e.
(17) Di sconnect the two forty pi n connectors from
the ri ght of the steeri ng col umn (Fi g. 29).
(18) Remove the cl i nch bol t hol di ng upper the
steeri ng shaft to the l ower steeri ng shaft (Fi g. 29).
Fig. 25 Range Indicator Cable
Fig. 26 Heat Duct
Fig. 27 Lower Supports
(19) Separate the upper steeri ng shaft from the
l ower steeri ng shaft.
(20) Remove the nuts hol di ng the i nstrument
panel frame to the di e-cast brake pedal support on
each si de of the steeri ng col umn.
(21) Wi th mechani cal transmi ssi on range i ndi ca-
tor:
(a) Remove the i ndi cator cabl e l oop.
(b) Remove the cl i p hol di ng gear shi ft cabl e end
to the gear sel ector adapter.
(c) Pul l the cabl e end from gear sel ector.
(d) Di sconnect the cl i p for the i ndi cator cabl e
and gui de tube from the shi ft cabl e bracket and
move out of the way.
(22) Remove the nut hol di ng gear shi ft cabl e
bracket to the i nstrument panel frame.
(23) Remove the bracket from the i nstrument
panel .
(24) Remove the screw hol di ng hood rel ease handl e
to the i nstrument panel .
(25) Remove the bol t hol di ng the hood rel ease han-
dl e to the i nstrument panel .
(26) Posi ti on the hood rel ease handl e out of the
way.
(27) Remove the i nstrument panel top cover.
(28) Di sconnect the wi re connector from the HVAC
wi re harness behi nd the gl ove box area.
(29) Remove the bol ts hol di ng the i nstrument
panel frame to the brackets on cowl si de panel s (Fi g.
30) and (Fi g. 31).
(30) Loosen, but do not remove, the pi vot bol ts
hol di ng the i nstrument panel to the cowl panel s.
panel frame to the dash panel bel ow wi ndshi el d
openi ng.
(32) Remove the i nstrument panel from vehi cl e.
INSTALLATION
Fig. 28 Junction Block and Body Control Module
Connectors
Fig. 29 40 Way Connectors Location
Fig. 30 Passenger Side Instrument Panel
INSTRUMENT PANEL LEFT END COVER
REMOVAL
(1) Open dri ver si de front door (Fi g. 32).
(2) Remove l ower steeri ng col umn cover as neces-
sary to gai n cl earance for end cover removal .
(3) Remove attachi ng screw
(4) Di sengage cl i ps hol di ng end cover to i nstru-
ment panel .
(5) Remove i nstrument panel end cover and foam
pad coveri ng the A/C i nl et projecti on of the end cover
i f equi pped.
INSTALLATION
INSTRUMENT PANEL LOUVERS
CENTER LOUVER HOUSING
REMOVAL
(1) Remove the i nstrument cl uster bezel . Refer to
I nstrument Cl uster Bezel removal and i nstal l ati on
procedures.
(2) Pl ace cl uster bezel on a cl ean surface face down
wi th the head l amp swi tch to the ri ght si de (Fi g. 33).
(3) Usi ng a fl at bl aded tool , rel ease the l ouver
housi ng l ocks tabs (Fi g. 34).
(4) Rel ease the upper l eft l ock tab fi rst, then the
two l ower l ouver tabs.
(5) Appl yi ng pressure on the housi ng, rel ease the
upper ri ght l ock tab and the l ower ri ght.
(6) Push out the l ouver housi ng from the cl uster
bezel .
INSTALLATION
(1) Veri fy the functi on of the vanes.
(2) Set l ouver housi ng i nto the cl uster bezel .
(3) Usi ng care do not push on the vanes, appl y
pressure on outer edge of the housi ng and push l ou-
ver housi ng i nto pl ace.
(4) After i n pl ace check functi on of the vanes.
LEFT LOUVER HOUSING
REMOVAL
I nstrument Cl uster Bezel Removal and I nstal l ati on
procedures.
Fig. 31 Drivers Side instrument Panel
Fig. 32 Instrument Panel Left End Cover
housi ng l ocks tabs.
other upper l ock tab.
l ower l ock tabs.
bezel .
INSTALLATION
(2) Set l ouver housi ng i nto the cl uster bezel and
al i gn the sl ot of the housi ng wi th the T l ocati on pi ns.
PASSENGER SIDE LOUVERS
The i nner, outer l ouver and i nner, outer housi ng
are servi ceabl e.
REMOVAL
(1) Usi ng medi um fl at bl ade tool , posi ti on i t i n
between the ri ght si de of l ouver and the housi ng
(Fi g. 35).
(2) Twi st the tool to rel ease the pi vot pi n from the
l ouver and pul l outward ti l l rel eased from pi n.
(3) Pl ace tool on the other si de of l ouver and
rel ease the other pi vot pi n and pul l housi ng free from
the i nstrument panel . Use the same procedure for
ei ther i nner or outer l ouver.
INSTALLATION
The i nner and outer l ouvers have di fferent si ze
pi vot pi ns on the housi ng. The outer housi ng has a
l arger pi n on the ri ght si de then the i nner housi ng
(Fi g. 36). The l ouver have a surface cut out on the
ri ght si de of the housi ngs to note the proper si de.
(1) The ri ght pi vot pi n i s sl otted on both housi ngs.
So when al i gni ng l ouver tab wi th the pi n ensure that
they are l i ned up.
(2) Usi ng care, appl y pressure on outer edge of the
l ouver and push i nto pl ace.
(3) Rotate l ouver to ensure proper engagement.
PASSENGER SIDE LOUVER OUTER HOUSINGS
REMOVAL
(1) Usi ng a tri m sti ck, i nsert tri m sti ck between
the outer edge of the housi ng and the pad/panel vi nyl
coveri ng (Fi g. 37).
Fig. 34 Center Louver
Fig. 35 Removing Passenger Louver
Fig. 36 Passenger Side Louver and Housings
(2) Li ghtl y pry housi ng i nward and by hand pul l
the housi ng free from panel (Fi g. 38).
INSTALLATION
(1) Pl ace the sl otted pi n on the ri ght si de of the
openi ng.
(2) Set housi ng i n to posi ti on and push i nto pl ace.
The housi ng may need to be rocked to get the best fi t
wi thi n the openi ng.
INSTRUMENT PANEL TOP COVER
REMOVAL
(1) Remove A-pi l l ar tri m.
(2) Usi ng a tri m sti ck, di sengage cl i ps hol di ng rear
edge of top cover to i nstrument panel (Fi g. 39).
(3) Di sconnect wi re harness from message center.
(4) Pul l top cover rearward to di sengage hooks
hol di ng front of top cover to i nstrument panel .
(5) Remove top cover.
INSTALLATION
(1) Pl ace i nstrument panel top cover i n posi ti on on
vehi cl e.
(2) Push top cover forward to engage hooks to hol d
front of top cover to i nstrument panel .
(3) Connect wi re harness to message center.
(4) Engage cl i ps to hol d rear edge of top cover to
i nstrument panel .
(5) Pul l top cover rearward.
(6) I nstal l A-pi l l ar tri m.
INSTRUMENT PANEL RIGHT END COVER
REMOVAL
(1) Open passenger si de front door (Fi g. 40).
Fig. 37 Remove Housing
Fig. 38 Housing Being Removed
Fig. 39 Instrument Panel Top Cover
Fig. 40 Instrument Panel Right End Cover
(2) Di sengage cl i ps hol di ng ri ght end cover to
i nstrument panel .
i f equi pped.
INSTALLATION
JUNCTION BLOCK
REMOVAL
(3) Di sconnect four, forty-way connectors from
Juncti on Bl ock (Fi g. 41).
Body Control Modul e.
panel mounti ng.
Juncti on Bl ock.
(8) Sl i de Body Control Modul e downward to di s-
connect gui de studs on Juncti on Bl ock from BCM
ti ng bracket.
(9) Separate Juncti on Bl ock from Body Control
Modul e.
INSTALLATION
KNEE BLOCKER REINFORCEMENT
REMOVAL
(1) Remove l ower steeri ng col umn cover (Fi g. 42).
(2) Remove screws hol di ng knee bl ocker rei nforce-
ment to i nstrument panel .
(3) Remove rei nforcement.
INSTALLATION
(1) Pl ace rei nforcement i n posi ti on.
(2) I nstal l screws to hol d knee bl ocker rei nforce-
LOWER CONSOLE
REMOVAL
(1) Remove screws hol di ng l ower consol e to fl oor
bracket and i nstrument panel (Fi g. 43).
(2) Sl i de consol e rearward from around i nstrument
panel supports.
(3) Remove l ower consol e.
Fig. 41 Junction Block
Fig. 42 Knee Blocker Reinforcement
Fig. 43 Lower Console
INSTALLATION
(1) Pl ace l ower consol e i n posi ti on.
(2) Sl i de consol e forward around i nstrument panel
supports.
(3) I nstal l screws to hol d l ower consol e to fl oor
bracket and i nstrument panel .
LOWER INSTRUMENT PANEL
REMOVAL
(1) Remove the ri ght end cover.
(2) Remove the steeri ng col umn bezel .
(3) Remove the radi o bezel and the HVAC control .
(5) Remove the conveni ence cup hol der and track.
(7) Remove the gl ove box l atch stri ker.
(8) Remove the gl ove box l amp.
(9) Di sconnect the wi re connector from gl ove box
l amp.
(10) Remove the screws hol di ng the l ower i nstru-
ment panel to the rei nforcement frame around the
gl ove box openi ng (Fi g. 44).
(11) Remove the screw hol di ng the l ower i nstru-
ment panel to the ri ght si de of i nstrument panel .
(12) Remove the screw hol di ng the l ower i nstru-
ment panel to the upper i nstrument panel at the l eft
si de panel above the accel erator pedal .
(13) Remove the i nstrument cl uster bezel as neces-
sary to gai n access to the l ower i nstrument panel
screws.
(14) Remove the screw hol di ng i nstrument panel
to the upper panel bel ow the i nstrument cl uster.
(15) Remove the screws hol di ng rear of storage
pocket to the panel support frame.
(16) Remove the screws hol di ng the l ower i nstru-
ment panel to the upper i nstrument panel from
bel ow radi o.
(17) Remove the screws hol di ng l ower i nstrument
panel to the support frame i n fl oor consol e area.
(18) Separate the l ower i nstrument from the upper
i nstrument panel .
(19) Di sconnect the wi re connectors from back of
the 12 vol t outl et base.
(20) Remove the l ower i nstrument from vehi cl e.
INSTALLATION
LOWER STEERING COLUMN COVER
REMOVAL
(1) Remove screws hol di ng parki ng brake rel ease
handl e to i nstrument panel (Fi g. 45).
(2) Remove screws hol di ng bottom of l ower steer-
i ng col umn cover to i nstrument panel (Fi g. 46).
(3) Remove screw hol di ng ri ght si de of l ower steer-
i ng col umn cover to i nstrument panel .
Fig. 44 Lower Instrument Panel
Fig. 45 Park Brake Release Handle
Fig. 46 Lower Steering Column Cover
(4) Di sengage park brake rel ease cabl e case from
groove on end of rel ease handl e (Fi g. 47).
(5) Di sengage cabl e end pi vot from sl ot on rel ease
handl e (Fi g. 47).
INSTALLATION
For i nstal l ati on, reverse the above procedures,
MECHANICAL TRANSMISSION RANGE INDICATOR
REMOVAL
(3) Remove screws hol di ng mechani cal transmi s-
si on range i ndi cator to back of cl uster l ens.
(4) Remove mechani cal transmi ssi on range i ndi ca-
tor from cl uster l ens.
INSTALLATION
(1) Posi ti on transmi ssi on range i ndi cator on cl us-
ter l ens.
(2) I nstal l mechani cal range i ndi cator and attach-
i ng screws to back of cl uster l ens.
(3) I nstal l cl uster l ens.
MESSAGE CENTER
REMOVAL
(2) Remove i nstrument panel top cover. Refer to
i nstrument panel top cover removal procedures.
(3) Di sconnect the wi re connector from back of
message center.
(4) Remove screws hol di ng message center to
i nstrument panel top cover.
(5) Remove message center from i nstrument panel
top cover.
INSTALLATION
(1) Pl ace message center i n posi ti on on top cover.
(2) I nstal l screws to hol d message center to i nstru-
ment panel top cover.
(3) Connect wi re connector i nto back of message
center.
(4) I nstal l i nstrument panel top cover.
MESSAGE CENTER LAMP
REMOVAL
I nstrument Panel Top Cover Removal procedures.
(2) Locate the l amp i n questi on (Fi g. 48).
(3) Remove l amp and check l amp. I f l amp i s good
test the power suppl y to the l amp.
INSTALLATION
OUTLET (12 VOLT) BASE
REMOVAL
(1) Look i nsi de and note posi ti on of the retai ni ng
bosses (Fi g. 49).
(2) Usi ng external snap ri ng pl i ers wi th 90 degree
ti ps. I nsert pl i ers wi th ti ps agai nst bosses and
squeeze forci ng bosses out of base.
(3) Pul l out the base through mounti ng ri ng by
gentl y rocki ng pl i ers. A tool can be made to do the
same. Refer to (Fi g. 50).
(4) Di sconnect the base wi res.
(5) Set base asi de. Remove l i ght ri ng and di scon-
nect wi re.
INSTALLATION
(1) Posi ti on mount ri ng to the i nstrument panel
and feed the wi res through ri ng. I ndex the cap and
the mount ri ng wi th the i ndex tab at 9 ocl ock to the
key i n the i nstrument panel . I nstal l the ri ng.
(2) Connect wi res to base. Ori ent base al i gnment
ri b at 11 ocl ock to mate the groove i n mount ri ng at
the same l ocati on
(3) Push base i nto the bezel ti l l i t l ocks.
(4) I nstal l 12 vol t outl et cap and check operati on of
outl et or el ement.
OVER STEERING COLUMN BEZEL
REMOVAL
(2) Remove the screws hol di ng over steeri ng col -
umn bezel to the cl uster bezel (Fi g. 51).
(3) Remove over steeri ng col umn bezel from vehi -
cl e.
(4) Di sconnect the cl i ps hol di ng over col umn bezel
to the cl uster bezel .
(5) I f equi pped wi th tracti on control swi tch, di scon-
nect the wi re pi gtai l connector from the tracti on con-
trol swi tch.
(6) Remove the over steeri ng col umn bezel .
INSTALLATION
(1) Pl ace the over steeri ng col umn bezel i n posi ti on
and engage cl i ps to the cl uster bezel . I f equi pped
Fig. 48 Message Center Lamp Location
Fig. 49 Outlet Base Removal
Fig. 50 Tool For Outlet Removal
Fig. 51 Over Steering Column Bezel
wi th tracti on control swi tch connect the wi re pi gtai l
before engagi ng cl i ps.
(2) I nstal l the screws to hol d the over steeri ng col -
umn bezel to the cl uster bezel .
(3) I nstal l the l ower col umn cover.
POWER MIRROR SWITCH
REMOVAL
(2) Di sconnect wi re connector from back of power
mi rror swi tch.
(3) Di sengage l ock tabs above and bel ow the mi r-
ror swi tch.
(4) Pul l power mi rror swi tch from headl amp
swi tch bezel .
(5) Remove power mi rror swi tch.
INSTALLATION
POWER MIRROR SWITCH LAMP
REMOVAL
ter turn.
(3) Pul l bul b socket from back of power mi rror
swi tch.
INSTALLATION
RADIO BEZEL AND HVAC CONTROL
REMOVAL
(1) Remove conveni ence bi n - cup hol der. Refer to
Conveni ence Bi n - Cup Hol der Removal and I nstal l a-
(2) I nsert the tri m sti ck (speci al tool #C-4755)
between access cover and radi o bezel , above conve-
ni ence bi n - cup hol der.
(3) Careful l y pry the access cover from the i nstru-
ment panel (Fi g. 54).
(4) Separate the access cover from the vehi cl e.
(5) Remove conveni ence bi n - cup hol der track.
Refer to Conveni ence Bi n - Cup Hol der Track
Removal and I nstal l ati on procedures i n thi s secti on.
(6) Remove the attachi ng screws hol di ng bottom of
the bezel to i nstrument panel (Fi g. 55).
(7) Remove the attachi ng screws hol di ng top of the
bezel to the i nstrument panel .
(8) Remove the bezel from the i nstrument panel .
rear bl ower swi tch, i f equi pped.
(10) Di sconnect the wi re connector from the back
of the HVAC Control .
(11) Remove the bezel .
Fig. 52 Power Mirror Switch
Fig. 53 Power Mirror Switch Lamp
INSTALLATION
(1) Hol d the radi o bezel up and connect the wi re
connector i nto the back of the HVAC control .
(2) Connect the wi re connector i nto back of the
(3) Pl ace the radi o bezel i n posi ti on on the i nstru-
ment panel .
(4) I nstal l screws to hol d the top of radi o bezel to
i nstrument panel .
(5) I nstal l screws to the hol d bottom of the radi o
(6) I nstal l the access cover.
REAR HEATER-A/C SWITCH
REMOVAL
56).
(2) Remove screw hol di ng rear heater-A/C swi tch
to radi o bezel HVAC Control .
(3) Di sengage hook hol di ng bottom of swi tch to
radi o bezel HVAC Control .
(4) Remove swi tch from radi o bezel HVAC Control .
INSTALLATION
For i nstrument, reverse the above procedures.
REAR HEATER-A/C SWITCH LAMP
REMOVAL
(1) Remove radi o bezel HVAC Control .
ter (Fi g. 57).
(3) Pul l bul b socket from swi tch.
INSTALLATION
TRACTION CONTROL SWITCH
REMOVAL
(1) Remove the over steeri ng col umn bezel (Fi g.
51). Refer to Over Steeri ng Col umn Bezel Removal
procedure.
(2) Remove the two screws attachi ng tracti on con-
trol swi tch to the bezel .
INSTALLATION
For i nstal l ati on, reverse the above procedure.
Fig. 55 Radio Bezel and HVAC Control
Fig. 56 Rear Heater A/C Switch
Fig. 57 Rear Heater-A/C Switch Lamp Bulb
INSTRUMENT PANEL AND SYSTEMS
CONTENTS
page page
GENERAL INFORMATION
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . 1
HEADLAMP AND POWER MIRROR
SWITCH LAMP(S) . . . . . . . . . . . . . . . . . . . . . 1
INSTRUMENT CLUSTER . . . . . . . . . . . . . . . . . 2
DIAGNOSTIC PROCEDURES . . . . . . . . . . . . . . 2
HEADLAMP SWITCH . . . . . . . . . . . . . . . . . . . . 2
SELF DIAGNOSTIC TEST . . . . . . . . . . . . . . . . . 3
ASH RECEIVER CONVENIENCE
BIN LAMP MODULE . . . . . . . . . . . . . . . . . . 15
BODY CONTROL MODULE (BCM) . . . . . . . . . 16
CIGAR LIGHTER BASE . . . . . . . . . . . . . . . . . . 16
CONVENIENCE BIN . . . . . . . . . . . . . . . . . . . . 15
CONVENIENCE BIN - CUP HOLDER . . . . . . . 15
GLOVE BOX . . . . . . . . . . . . . . . . . . . . . . . . . . 17
GLOVE BOX LAMP AND SWITCH . . . . . . . . . 17
GLOVE BOX LOCK STRIKER . . . . . . . . . . . . . 17
HEADLAMP SWITCH . . . . . . . . . . . . . . . . . . . 18
HEADLAMP SWITCH LAMP(S) . . . . . . . . . . . 18
HVAC CONTROL LAMP . . . . . . . . . . . . . . . . . 18
INSTRUMENT CLUSTER . . . . . . . . . . . . . . . . 20
INSTRUMENT CLUSTER BACK PANEL . . . . . 18
INSTRUMENT CLUSTER BEZEL . . . . . . . . . . 18
INSTRUMENT CLUSTER LENS . . . . . . . . . . . 19
INSTRUMENT CLUSTER PRINTED
CIRCUIT BOARD . . . . . . . . . . . . . . . . . . . . . 19
INSTRUMENT CLUSTER SUBDIAL . . . . . . . . 20
INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . 20
INSTRUMENT PANEL LEFT END COVER . . . . 22
INSTRUMENT PANEL LOUVERS . . . . . . . . . . 22
INSTRUMENT PANEL RIGHT END COVER . . 25
INSTRUMENT PANEL TOP COVER . . . . . . . . 24
J UNCTION BLOCK . . . . . . . . . . . . . . . . . . . . . 25
KNEE BLOCKER REINFORCEMENT . . . . . . . . 25
LOWER CONSOLE . . . . . . . . . . . . . . . . . . . . . 26
LOWER INSTRUMENT PANEL . . . . . . . . . . . . 26
LOWER STEERING COLUMN COVER . . . . . . 27
MESSAGE CENTER . . . . . . . . . . . . . . . . . . . . 27
OVER STEERING COLUMN BEZEL . . . . . . . . 28
POWER MIRROR SWITCH . . . . . . . . . . . . . . 28
POWER MIRROR SWITCH LAMP . . . . . . . . . 28
RADIO BEZEL AND HVAC CONTROL . . . . . . . 29
REAR HEATER-A/C SWITCH . . . . . . . . . . . . . 29
REAR HEATER-A/C SWITCH LAMP . . . . . . . . 29
GENERAL INFORMATION
INTRODUCTION
The i nstrumentati on gauges on GS vehi cl es are
contai ned i n a subdi al assembl i es wi thi n the i nstru-
ment cl uster. The i ndi vi dual gauges are not servi ced
separatel y. I f one of the cl uster gauges becomes
faul ty the enti re subdi al woul d requi re repl acement
and al l gauges wi l l have to be cal i brated. Refer to the
HEADLAMP AND POWER MIRROR SWITCH
LAMP(S)
The Headl amp Swi tch and Power Mi rror Swi tch
l amps are shown i n (Fi g. 1). For repl acement of the
l amp(s) refer to Headl amp Swi tch Lamp(s) Removal
and I nstal l ati on procedures bel ow. Refer to Group 8T,
Power Mi rrors for mi rror test procedures.
NS/GS INSTRUMENT PANEL AND SYSTEMS 8E - 1
INSTRUMENT CLUSTER
The mechani cal i nstrument cl uster wi th a tachom-
eter i s equi pped wi th a el ectroni c vacuum fl uorescent
odometer, and tri p odometer di spl ay.
The i nstrument cl uster i s equi pped wi th the fol l ow-
i ng warni ng l amps (Fi g. 2).
Battery Vol tage
Li ft Gate Ajar
Low Cool ant
Low Wi ndshi el d Washer Fl ui d Level
Door Ajar
Gl ow Pl ug I ndi cator
Low Fuel Level
GS vehi cl e i nstrument cl usters are equi pped wi th a
sel f di agnosti c test feature to hel p i denti fy el ectroni c
probl ems. Pri or to any test, perform Sel f Di agnosti c
Test. The sel f di agnosti c system moni tors the CCD
bus messages. I f an el ectroni c probl em occurs, a
Di agnosti c Troubl e Code (DTC) wi l l be di spl ayed i n
the odometer wi ndow of the cl uster.
The fol l owi ng CCD bus messages are conti nuousl y
moni tored by the di agnosti c system:
HEADLAMP SWITCH
Usi ng a Di gi tal Mul ti meter, equi pped wi th a di ode
test to perform the Headl amp Swi tch Test bel ow (Fi g.
3).
Swi tch posi ti on possi bi l i ti es are open (no conti nu-
i ty), conti nui ty, resi stance val ue i n ohms, or di ode
test. Use the val ues i n the thi rd col umn to determi ne
meter setti ng. I f Headl amp Swi tch i s not wi thi n spec-
i fi cati ons repl ace as necessary.
Fig. 2 Instrument Cluster
Fig. 1 Headlamp and Mirror Switch Lamps
8E - 2 INSTRUMENT PANEL AND SYSTEMS NS/GS
SELF DIAGNOSTIC TEST
Wi th the i gni ti on swi tch i n the OFF posi ti on,
depress the TRI P and RESET buttons. Whi l e hol di ng
the TRI P and RESET button turn the i gni ti on swi tch
ON. Conti nue to hol d the TRI P and RESET buttons
unti l the word CODE appears i n the odometer wi n-
dows (about fi ve seconds). I f a probl em exi sts, the
system wi l l di spl ay di agnosti c troubl e codes. I f no
probl em exi sts the code 999 (End Test) wi l l momen-
tari l y appear.
DIM TEST
dow, the cl usters vacuum fl uorescent (VF) di spl ays
wi l l di m down. I f the VF di spl ay bri ghtness does not
change, a probl em exi sts i n the cl uster.
CLUSTER CALIBRATION TABLE
Speedometer Calibration Point
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 Km/h (0 mph)
2 . . . . . . . . . . . . . . . . . . . . . . . . . 40 Km/h (20 mph)
3 . . . . . . . . . . . . . . . . . . . . . . . . . 80 Km/h (55 mph )
4 . . . . . . . . . . . . . . . . . . . . . . . . 120 Km/h (75 mph)
Tachometer Calibration Point
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 rpm
2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1000 rpm
3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3000 rpm
4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4000 rpm
Fuel Gauge Calibration Point
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Empty (E)
2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/8 Fi l l ed
3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/4 Fi l l ed
4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ful l (F)
Temp Gauge Calibration Point
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Col d (C)
2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Low Normal
3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hi gh Normal
4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hot (H)
Fig. 3 Headlamp Switch Test
INSTRUMENT CLUSTER DTC CHART
DTC DESCRIPTION
110 Memory Fault in cluster
111 Calibration fault in cluster
921 Odometer fault from BCM
940 No tachometer messages from BCM
CALIBRATION TEST
dow, each of the cl usters gauge poi nters wi l l move
sequenti al l y through each cal i brati on poi nt. The Cal -
i brati on Tabl e contai ns the proper cal i brati on poi nts
for each gauge. I f the gauge poi nters are not cal i -
brated, a probl em exi sts i n the cl uster. I f any gauge
i s out of cal i brati on i t wi l l have to be cal i brated usi ng
a scan tool (DRB I I I ). Refer to the proper Body Di ag-
nosti c Procedure Manual for cal i brati on procedures.
ODOMETER SEGMENT TEST
dow, each di gi t of the odometer wi l l i l l umi nate
sequenti al l y. I f a segment i n the odometer does not
i l l umi nate normal l y, a probl em exi sts i n the di spl ay.
CONDITIONS
Refer to the fol l owi ng charts for possi bl e/probl ems/
causes and correcti ons.
Speedometer
Tachometer
Fuel Gauge
Temperature Gauge
Odometer
CONVENIENCE BIN - CUP HOLDER
REMOVAL
(1) Pul l the conveni ence bi n open (Fi g. 4).
(2) Push l ock tab at rear center downward.
(3) Pul l the conveni ence bi n - cup hol der from
track i n i nstrument panel .
(4) Remove conveni ence bi n - cup hol der.
INSTALLATION
ASH RECEIVER CONVENIENCE BIN LAMP
MODULE
REMOVAL
(1) Pul l out ash recei ver/cup hol der.
(2) I nsert tri m sti ck between access cover above
cup hol der and center consol e.
(3) Careful l y pry access cover from center consol e
(Fi g. 5).
(4) Separate access cover from vehi cl e.
(5) Remove screw from ash recei ver l amp modul e.
(6) Careful l y pul l l amp modul e and wi ri ng rear-
ward from i nstrument panel (Fi g. 6).
(7) Di sconnect l amp modul e from the wi ri ng con-
nector.
INSTALLATION
CONVENIENCE BIN
REMOVAL
(1) Remove the ash recei ver/cup hol der from the
i nstrument panel .
(2) Remove the screw access cover from the bottom
of the radi o bezel (Fi g. 5).
(3) Remove the center bezel .
(4) Remove the ash recei ver/cup hol der attachi ng
screws and pul l the ash recei ver/cup hol der track
rearward to di sengage the rear gui de studs from
i nstrument panel (Fi g. 7).
(5) Remove the ash recei ver/cup hol der.
Fig. 4 Convenience Bin Cup Holder
Fig. 5 Ash Receiver Access Cover
Fig. 6 Ash Reveiver Lamp Module
INSTALLATION
BODY CONTROL MODULE (BCM)
REMOVAL
Body Control Modul e (BCM)
panel mounti ng bracket (Fi g. 8).
Juncti on Bl ock.
(7) Sl i de Body Control Modul e downward to di sen-
gage gui de studs on Juncti on Bl ock from channel s on
(8) Remove Body Control Modul e from Juncti on
Bl ock.
INSTALLATION
CIGAR LIGHTER BASE
REMOVAL
(1) Look i nsi de and note posi ti on of the retai ni ng
bosses (Fi g. 9).
(2) Usi ng external snap ri ng pl i ers wi th 90 degree
ti ps. I nsert pl i ers wi th ti ps agai nst bosses and
squeeze forci ng bosses out of base.
(3) Pul l out base, through mounti ng ri ng, gentl y
rocki ng pl i ers.
(4) Di sconnect the base wi res.
(5) Set base asi de. Remove l i ght ri ng and di scon-
nect wi re.
INSTALLATION
(1) Connect wi re to l i ght ri ng and i nstal l ri ng.
(2) Connect wi res to base.
(3) Push base i nto the bezel ti l l i t l ocks.
(4) I nstal l l i ghter el ement and check operati on of
el ement.
Fig. 7 Ash Receiver/Cup Holder Track RHD
Fig. 8 Body Control Module Location
Fig. 9 Cigar Lighter Base Removal
GLOVE BOX
REMOVAL (FIG. 4)
(1) Open gl ove box (Fi g. 10).
door.
(3) Pi vot gl ove box downward and di sengage hi nge
hooks from i nstrument panel .
INSTALLATION
(1) Pl ace gl ove box i n posi ti on.
(2) Engage hi nge hooks i nto i nstrument panel and
pi vot gl ove box upward.
(3) Engage cl i p to hol d checkstraps to gl ove box
door.
(4) Cl ose gl ove box door.
REMOVAL
(3) Di sengage wi re connector from gl ove box l amp
and swi tch.
(4) Remove gl ove box l amp and swi tch.
(5) Remove l amp (Fi g. 12).
INSTALLATION
GLOVE BOX LOCK STRIKER
REMOVAL
door.
(3) Remove screws hol di ng l ock stri ker to i nstru-
ment panel .
(4) Remove gl ove box l ock stri ker.
INSTALLATION
Fig. 10 Glove Box
Fig. 12 Glove Box Lamp
Fig. 13 Glove Box Lock Striker
HEADLAMP SWITCH
REMOVAL
(2) Remove screws hol di ng the headl amp swi tch
bezel to cl uster bezel .
(3) Di sconnect the wi re connectors from the head-
l amp swi tch and wi re connector from the power mi r-
ror swi tch.
(4) Remove headl amp swi tch bezel from cl uster
bezel .
INSTALLATION
HEADLAMP SWITCH LAMP(S)
REMOVAL
(1) Remove i nstrument cl uster bezel .
(2) Di sconnect wi re connectors.
(3) Remove headl amp swi tch bezel from i nstru-
ment cl uster bezel .
(5) Pul l bul b socket from headl amp swi tch.
INSTALLATION
HVAC CONTROL LAMP
REMOVAL
16).
(2) Remove rear cover from HVAC control .
ter turn.
(4) Pul l bul b socket from HVAC.
INSTALLATION
INSTRUMENT CLUSTER BACK PANEL
REMOVAL
(2) Remove screws hol di ng back panel to i nstru-
ment cl uster (Fi g. 17).
(3) Remove back panel .
INSTALLATION
INSTRUMENT CLUSTER BEZEL
REMOVAL
(1) Remove steeri ng col umn cover.
(2) Remove over steeri ng col umn bezel (Fi g. 18).
(3) Remove l eft end cover.
(4) Remove screw at l eft end of cl uster bezel and
headl amp swi tch.
Fig. 14 Headlamp Switch
Fig. 15 Headlamp Switch Lamp
Fig. 16 HVAC Control Lamps
(5) Remove screws hol di ng cl uster bezel to i nstru-
ment panel from each si de of steeri ng col umn.
(6) Di sconnect cl i p hol di ng cl uster bezel to i nstru-
ment panel from above ri ght vent l ouver.
(7) Separate cl uster bezel from i nstrument panel .
(8) Di sconnect wi re connectors from back of the
bezel .
INSTALLATION
(1) Connect wi re connectors i nto back of the bezel .
(2) Pl ace cl uster bezel i n posi ti on on i nstrument
panel . Use care not to pl ace hands on l ouvers.
(3) Connect cl i ps to hol d cl uster bezel to i nstru-
ment panel . Use care not to add pressure on the A/C
l ouvers to seat the cl uster bezel cl i ps.
(4) I nstal l screws to hol d cl uster bezel to i nstru-
ment panel on each si de of steeri ng col umn.
(5) I nstal l screw at l eft end of cl uster bezel and
headl amp swi tch.
(6) I nstal l l eft end cover.
(7) I nstal l over steeri ng col umn bezel .
INSTRUMENT CLUSTER LENS
REMOVAL
(2) Remove screws hol di ng l ens to i nstrument cl us-
ter (Fi g. 19).
(3) Remove l ens from cl uster.
INSTALLATION
INSTRUMENT CLUSTER PRINTED CIRCUIT BOARD
REMOVAL
(2) Remove the i nstrument cl uster back panel .
(3) Di sconnect the el ectroni c cl uster wi re connector
from the pri nted ci rcui t board (Fi g. 20).
(4) Remove the screws hol di ng wi re connector
i nsul ator to the i nstrument cl uster shel l and the
pri nted ci rcui t board.
Fig. 17 Instrument Cluster Back Panel
Fig. 19 Instrument Cluster Lens
Fig. 20 Instrument Cluster Printed Circuit Board
(5) Remove the screws hol di ng pri nted ci rcui t
board to the cl uster shel l .
(6) Remove the pri nted ci rcui t board from the cl us-
ter.
INSTALLATION
After i nstal l i ng the pri nt ci rcui t board i t wi l l have to
be cal i brated usi ng a scan tool (DRB I I I ). Refer to the
NOTE: Speedometer and/or Tachometer will not
operate properly until all gauges have been cali-
brated
REMOVAL
(3) Di sconnect temperature/fuel gauge and tachom-
eter termi nal s from connectors i n cl uster by pul l i ng
subdi al strai ght away from cl uster (Fi g. 21).
(4) Remove subdi al from cl uster.
INSTALLATION
INSTRUMENT CLUSTER
REMOVAL
(2) Remove screws hol di ng i nstrument cl uster to
i nstrument panel .
(3) Rotate top of cl uster outward.
(4) Remove i nstrument cl uster from i nstrument
panel .
(5) Di sconnect wi re connector from back of i nstru-
ment cl uster.
INSTALLATION
INSTRUMENT PANEL
The i nstrument panel i s removed as a uni t. The
steeri ng col umn and wi ri ng harnesses are assembl ed
i nto the panel before i nstal l ati on. Servi ce procedures
for i nteri or tri m not rel ated to the i nstrument panel
can be found i n Group 23, Body.
REMOVAL
(1) Di sconnect the battery, negati ve cabl e fi rst.
(3) Remove the screw hol di ng the l ower heat duct
to the i nstrument panel support (Fi g. 23).
(4) Di sconnect the heat duct from the vehi cl e.
the i nstrument panel frame (Fi g. 24).
Fig. 21 Instrument Cluster Subdial
Fig. 22 Instrument Panel
Fig. 23 Heat Duct
the fl oor pan.
(7) Remove the ri ght and l eft end covers.
(8) Di sconnect the wi re connectors from the Pas-
senger Ai rbag Modul e.
(9) Remove the front door si l l tri m covers.
(10) Remove the A-pi l l ar tri m covers.
(12) Di sconnect the antenna l ead connector from
behi nd the gl ove box.
(14) Remove the knee bl ocker panel .
(15) Di sconnect the l ower two, forty pi n wi re har-
ness connectors, from the mai n Juncti on Bl ock near
l eft cowl si de panel (Fi g. 25).
(16) Di sconnect the i nstrument panel wi re harness
connector from the bottom of Body Control Modul e.
(17) Di sconnect the two forty pi n connectors from
the ri ght of the steeri ng col umn (Fi g. 26).
(18) Remove the cl i nch bol t hol di ng upper the
steeri ng shaft to the l ower steeri ng shaft (Fi g. 26).
(19) Separate the upper steeri ng shaft from the
l ower steeri ng shaft.
(20) Remove the nuts hol di ng the i nstrument
panel frame to the di e-cast brake pedal support on
each si de of the steeri ng col umn.
(21) Wi th mechani cal transmi ssi on range i ndi ca-
tor:
(a) Remove the i ndi cator cabl e l oop.
(b) Remove the cl i p hol di ng gear shi ft cabl e end
to the gear sel ector adapter.
(c) Pul l the cabl e end from gear sel ector.
(d) Di sconnect the cl i p for the i ndi cator cabl e
and gui de tube from the shi ft cabl e bracket and
move out of the way.
(22) Remove the nut hol di ng gear shi ft cabl e
bracket to the i nstrument panel frame.
(23) Remove the bracket from the i nstrument
panel .
(24) Remove the screw hol di ng hood rel ease handl e
to the i nstrument panel .
(25) Remove the bol t hol di ng the hood rel ease han-
dl e to the i nstrument panel .
(26) Posi ti on the hood rel ease handl e out of the
way.
(27) Remove the i nstrument panel top cover.
(28) Di sconnect the wi re connector from the HVAC
wi re harness behi nd the gl ove box area.
Fig. 24 Lower Supports
Fig. 25 Junction Block and Body Control Module
Connectors
Fig. 26 40 Way Connectors Location
panel frame to the brackets on cowl si de panel s (Fi g.
27) and (Fi g. 28).
(30) Loosen, but do not remove, the pi vot bol ts
hol di ng the i nstrument panel to the cowl panel s.
panel frame to the dash panel bel ow wi ndshi el d
openi ng.
(32) Remove the i nstrument panel from vehi cl e.
INSTALLATION
INSTRUMENT PANEL LEFT END COVER
REMOVAL
(1) Open dri ver si de front door (Fi g. 29).
(2) Remove l ower steeri ng col umn cover as neces-
sary to gai n cl earance for end cover removal .
(3) Remove attachi ng screw
(4) Di sengage cl i ps hol di ng end cover to i nstru-
ment panel .
i f equi pped.
INSTALLATION
INSTRUMENT PANEL LOUVERS
CENTER LOUVER HOUSING
REMOVAL
I nstrument Cl uster Bezel removal and i nstal l ati on
procedures.
housi ng l ocks tabs (Fi g. 31).
two l ower l ouver tabs.
Fig. 27 Passenger Side Instrument Panel
Fig. 28 Drivers Side instrument Panel
Fig. 29 Instrument Panel Left End Cover
upper ri ght l ock tab and the l ower ri ght.
bezel .
INSTALLATION
(2) Set l ouver housi ng i nto the cl uster bezel .
LEFT LOUVER HOUSING
REMOVAL
I nstrument Cl uster Bezel Removal and I nstal l ati on
procedures.
housi ng l ocks tabs.
other upper l ock tab.
l ower l ock tabs.
bezel .
INSTALLATION
(2) Set l ouver housi ng i nto the cl uster bezel and
al i gn the sl ot of the housi ng wi th the T l ocati on pi ns.
PASSENGER SIDE LOUVERS
The i nner, outer l ouver and i nner, outer housi ng
are servi ceabl e.
REMOVAL
(1) Usi ng medi um fl at bl ade tool , posi ti on i t i n
between the ri ght si de of l ouver and the housi ng
(Fi g. 32).
(2) Twi st the tool to rel ease the pi vot pi n from the
l ouver and pul l outward ti l l rel eased from pi n.
(3) Pl ace tool on the other si de of l ouver and
rel ease the other pi vot pi n and pul l housi ng free from
the i nstrument panel . Use the same procedure for
ei ther i nner or outer l ouver.
Fig. 31 Center Louver
Fig. 32 Removing Passenger Louver
INSTALLATION
The i nner and outer l ouvers have di fferent si ze
pi vot pi ns on the housi ng. The outer housi ng has a
l arger pi n on the ri ght si de then the i nner housi ng
(Fi g. 33). The l ouver have a surface cut out on the
ri ght si de of the housi ngs to note the proper si de.
(1) The ri ght pi vot pi n i s sl otted on both housi ngs.
So when al i gni ng l ouver tab wi th the pi n ensure that
they are l i ned up.
(2) Usi ng care, appl y pressure on outer edge of the
l ouver and push i nto pl ace.
(3) Rotate l ouver to ensure proper engagement.
PASSENGER SIDE LOUVER OUTER HOUSINGS
REMOVAL
(1) Usi ng a tri m sti ck, i nsert tri m sti ck between
the outer edge of the housi ng and the pad/panel vi nyl
coveri ng (Fi g. 34).
(2) Li ghtl y pry housi ng i nward and by hand pul l
the housi ng free from panel (Fi g. 35).
INSTALLATION
(1) Pl ace the sl otted pi n on the ri ght si de of the
openi ng.
(2) Set housi ng i n to posi ti on and push i nto pl ace.
The housi ng may need to be rocked to get the best fi t
wi thi n the openi ng.
INSTRUMENT PANEL TOP COVER
REMOVAL
(2) Usi ng a tri m sti ck, di sengage cl i ps hol di ng rear
edge of top cover to i nstrument panel (Fi g. 36).
(3) Di sconnect wi re harness from message center.
(4) Pul l top cover rearward to di sengage hooks
hol di ng front of top cover to i nstrument panel .
(5) Remove top cover.
Fig. 33 Passenger Side Louver and Housings
Fig. 34 Remove Housing
Fig. 35 Housing Being Removed
Fig. 36 Instrument Panel Top Cover
INSTALLATION
(1) Pl ace i nstrument panel top cover i n posi ti on on
vehi cl e.
(2) Push top cover forward to engage hooks to hol d
front of top cover to i nstrument panel .
(3) Connect wi re harness to message center.
(4) Engage cl i ps to hol d rear edge of top cover to
i nstrument panel .
(5) Pul l top cover rearward.
INSTRUMENT PANEL RIGHT END COVER
REMOVAL
(1) Open passenger si de front door (Fi g. 37).
(2) Di sengage cl i ps hol di ng ri ght end cover to
i nstrument panel .
i f equi pped.
INSTALLATION
JUNCTION BLOCK
REMOVAL
(3) Di sconnect four, forty-way connectors from
Juncti on Bl ock (Fi g. 38).
Body Control Modul e.
panel mounti ng.
Juncti on Bl ock.
(8) Sl i de Body Control Modul e downward to di s-
connect gui de studs on Juncti on Bl ock from BCM
ti ng bracket.
(9) Separate Juncti on Bl ock from Body Control
Modul e.
INSTALLATION
KNEE BLOCKER REINFORCEMENT
REMOVAL
(1) Remove l ower steeri ng col umn cover (Fi g. 39).
(2) Remove screws hol di ng knee bl ocker rei nforce-
Fig. 37 Instrument Panel Right End Cover
Fig. 38 Junction Block
Fig. 39 Knee Blocker Reinforcement
(3) Remove rei nforcement.
INSTALLATION
(1) Pl ace rei nforcement i n posi ti on.
(2) I nstal l screws to hol d knee bl ocker rei nforce-
LOWER CONSOLE
REMOVAL
(1) Remove screws hol di ng l ower consol e to fl oor
bracket and i nstrument panel (Fi g. 40).
(2) Sl i de consol e rearward from around i nstrument
panel supports.
INSTALLATION
(1) Pl ace l ower consol e i n posi ti on.
(2) Sl i de consol e forward around i nstrument panel
supports.
(3) I nstal l screws to hol d l ower consol e to fl oor
bracket and i nstrument panel .
LOWER INSTRUMENT PANEL
REMOVAL
(1) Remove ri ght end cover.
(2) Remove steeri ng col umn bezel .
(3) Remove radi o bezel and HVAC control .
(5) Remove ash recei ver cup hol der and track.
(7) Remove gl ove box l atch stri ker.
(8) Remove gl ove box l amp.
(9) Di sconnect wi re connector from gl ove box l amp.
(10) Remove screws hol di ng l ower i nstrument
panel to rei nforcement frame around gl ove box open-
i ng (Fi g. 41).
Fig. 40 Lower Console
Fig. 41 Lower Instrument Panel
(11) Remove screw hol di ng l ower i nstrument panel
to ri ght si de of i nstrument panel .
(12) Remove screw hol di ng l ower i nstrument panel
to upper i nstrument panel at l eft si de panel above
accel erator pedal .
(13) Remove i nstrument cl uster bezel as necessary
to gai n access to l ower i nstrument panel screws.
(14) Remove screw l ower hol di ng i nstrument panel
to upper panel bel ow i nstrument cl uster.
(15) Remove screws hol di ng rear of storage pocket
to panel support frame.
panel to upper i nstrument panel from bel ow radi o.
panel to support frame i n fl oor consol e area.
(18) Separate l ower i nstrument from upper i nstru-
ment panel .
(19) Di sengage wi re connectors from back of acces-
sory pl ug.
(20) Separate l ower i nstrument from vehi cl e.
INSTALLATION
LOWER STEERING COLUMN COVER
REMOVAL
(1) Remove screws hol di ng parki ng brake rel ease
handl e to i nstrument panel (Fi g. 42).
(2) Remove screws hol di ng bottom of l ower steer-
i ng col umn cover to i nstrument panel (Fi g. 43).
(3) Remove screw hol di ng ri ght si de of l ower steer-
i ng col umn cover to i nstrument panel .
(4) Di sengage park brake rel ease cabl e case from
groove on end of rel ease handl e (Fi g. 44).
(5) Di sengage cabl e end pi vot from sl ot on rel ease
handl e (Fi g. 44).
INSTALLATION
For i nstal l ati on, reverse the above procedures,
MESSAGE CENTER
REMOVAL
i nstrument panel top cover removal procedures.
(3) Di sconnect the wi re connector from back of
message center.
(4) Remove screws hol di ng message center to
i nstrument panel top cover.
(5) Remove message center from i nstrument panel
top cover.
Fig. 43 Lower Steering Column Cover
INSTALLATION
(1) Pl ace message center i n posi ti on on top cover.
(2) I nstal l screws to hol d message center to i nstru-
ment panel top cover.
(3) Connect wi re connector i nto back of message
center.
OVER STEERING COLUMN BEZEL
REMOVAL
(2) Remove the screws hol di ng over steeri ng col -
umn bezel to the cl uster bezel (Fi g. 45).
(3) Remove over steeri ng col umn bezel from vehi -
cl e.
(4) Di sconnect the cl i ps hol di ng over col umn bezel
to the cl uster bezel .
(5) I f equi pped wi th tracti on control swi tch, di scon-
nect the wi re pi gtai l connector from the tracti on con-
trol swi tch.
(6) Remove the over steeri ng col umn bezel .
INSTALLATION
(1) Pl ace the over steeri ng col umn bezel i n posi ti on
and engage cl i ps to the cl uster bezel . I f equi pped
wi th tracti on control swi tch connect the wi re pi gtai l
before engagi ng cl i ps.
(2) I nstal l the screws to hol d the over steeri ng col -
umn bezel to the cl uster bezel .
(3) I nstal l the l ower col umn cover.
POWER MIRROR SWITCH
REMOVAL
mi rror swi tch.
(3) Di sengage l ock tabs above and bel ow the mi r-
ror swi tch.
(4) Pul l power mi rror swi tch from headl amp
swi tch bezel .
(5) Remove power mi rror swi tch.
INSTALLATION
POWER MIRROR SWITCH LAMP
REMOVAL
ter turn.
(3) Pul l bul b socket from back of power mi rror
swi tch.
Fig. 45 Over Steering Column Bezel
Fig. 46 Power Mirror Switch
Fig. 47 Power Mirror Switch Lamp
INSTALLATION
RADIO BEZEL AND HVAC CONTROL
REMOVAL
(1) Remove screw access cover (Fi g. 48).
(2) Remove the attachi ng screws hol di ng bottom of
the bezel to i nstrument panel .
(3) Remove the attachi ng screws hol di ng top of the
(4) Remove the bezel from the i nstrument panel .
(6) Di sconnect the wi re connector from the back of
the HVAC Control .
(7) Remove the bezel .
INSTALLATION
(1) Hol d the radi o bezel up and connect the wi re
connector i nto the back of the HVAC control .
(2) Connect the wi re connector i nto back of the
(3) Pl ace the radi o bezel i n posi ti on on the i nstru-
ment panel .
(4) I nstal l screws to hol d the top of radi o bezel to
i nstrument panel .
(5) I nstal l screws to the hol d bottom of the radi o
(6) I nstal l the access cover.
REAR HEATER-A/C SWITCH
REMOVAL
(1) Remove radi o bezel and HVAC Control (Fi g. 49).
(2) Remove screw hol di ng rear heater-A/C swi tch
to radi o bezel HVAC Control .
(3) Di sengage hook hol di ng bottom of swi tch to
radi o bezel HVAC Control .
(4) Remove swi tch from radi o bezel HVAC Control .
INSTALLATION
For i nstrument, reverse the above procedures.
REAR HEATER-A/C SWITCH LAMP
REMOVAL
(1) Remove radi o bezel HVAC Control .
ter (Fi g. 50).
(3) Pul l bul b socket from swi tch.
INSTALLATION
Fig. 49 Rear Heater A/C Switch
Fig. 50 Rear Heater-A/C Switch Lamp Bulb
AUDIO SYSTEMS
CONTENTS
page page
GENERAL INFORMATION
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . 1
ANTENNA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
CHOKEINFINITY SPEAKERS . . . . . . . . . . . . . . 2
INTERFERENCE ELIMINATION . . . . . . . . . . . . . . 1
NAME BRAND SPEAKER RELAY . . . . . . . . . . . . 3
RADIO IGNITION INTERFERENCE . . . . . . . . . . . 2
RADIOS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
REMOTE RADIO SWITCHES . . . . . . . . . . . . . . . . 3
ANTENNA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
AUDIO SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 4
RADIO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
ANTENNA EXTENSION CABLE . . . . . . . . . . . . . . 7
ANTENNA MAST AND CABLE LEAD . . . . . . . . . 7
DPILLAR SPEAKER . . . . . . . . . . . . . . . . . . . . 10
FRONT DOOR SPEAKER . . . . . . . . . . . . . . . . . . . 9
INSTRUMENT PANEL SPEAKER . . . . . . . . . . . . . 8
QUARTER PANEL SPEAKER . . . . . . . . . . . . . . . 10
RADIO/TAPE/CD PLAYER . . . . . . . . . . . . . . . . . . 8
GENERAL INFORMATION
INTRODUCTION
Operati ng i nstructi ons for the factory i nstal l ed
audi o systems can be found i n the Owners Manual
provi ded wi th the vehi cl e.
NS vehi cl es are equi pped wi th an I gni ti on Off
Draw (I OD) fuse i n the power di stri buti on center
l ocated i n the engi ne compartment. After the I OD
fuse or battery has been di sconnected, the radi o sta-
ti on sets and cl ock wi l l requi re resetti ng.
ANTENNA
Al l model s use a fi xed-l ength stai nl ess steel rod-
type antenna mast, i nstal l ed at the ri ght front fender
of the vehi cl e. The antenna mast i s connected to the
center wi re of the coaxi al antenna cabl e, and i s not
grounded to any part of the vehi cl e.
To el i mi nate stati c, the antenna base must have a
good ground. The coaxi al antenna cabl e shi el d (the
outer wi re mesh of the cabl e) i s grounded to the
antenna base and the radi o chassi s.
The antenna coaxi al cabl e has an addi ti onal di s-
connect, l ocated near the ri ght end of the i nstrument
panel . Thi s addi ti onal di sconnect al l ows the i nstru-
ment panel assembl y to be removed and i nstal l ed
wi thout removi ng the radi o.
The factory-i nstal l ed El ectroni cal l y Tuned Radi os
(ETRs) automati cal l y compensate for radi o antenna
tri m. Therefore, no antenna tri mmer adjustment i s
requi red or possi bl e when repl aci ng the recei ver or
the antenna.
INTERFERENCE ELIMINATION
Some components used on the vehi cl es are
equi pped wi th a capaci tor to suppress radi o fre-
quency i nterference/stati c.
Capaci tors are mounted i n vari ous l ocati ons i nter-
nal to the generator, i nstrument cl uster and wi nd-
shi el d wi per motor.
To el i mi nate radi o i nterference, ground straps are
used i n di fferent areas of the vehi cl e. These ground
ci rcui ts shoul d be securel y ti ghtened to assure good
metal to metal contact. The ground straps conduct
very smal l hi gh frequency el ectri cal si gnal s to ground
and requi re cl ean surface contact area. The radi o
ground i s suppl i ed from the i nstrument panel har-
ness and i s attached to the rear of the radi o. Some
engi nes have other ground straps to el i mi nate fur-
ther radi o i nterference:
Radi o chassi s to i nstrument panel structure
Engi ne to dash panel
Engi ne to chassi s
A/C h val ve to dash panel
Radi o resi stance type spark pl ug cabl es i n the hi gh
tensi on ci rcui t of the i gni ti on system compl ete the
i nterference suppressi on. Faul ty or deteri orated
spark pl ug wi res shoul d be repl aced.
RADIOS
Avai l abl e factory-i nstal l ed radi o recei vers for thi s
model i ncl ude an AM/FM/cassette (RAS sal es code),
an AM/FM/cassette/5-band graphi c equal i zer wi th CD
changer control feature (RBN sal es code), an AM/FM/
NS AUDIO SYSTEMS 8F - 1
CD/3-band graphi c equal i zer (RBR sal es code), or an
AM/FM/CD/cassette/3-band graphi c equal i zer (RAZ
sal es code).
Al l factory-i nstal l ed radi o recei vers are stereo El ec-
troni cal l y Tuned Radi os (ETR) and i ncl ude an el ec-
troni c di gi tal cl ock functi on.
Al l factory-i nstal l ed radi o recei vers, except the
RAS model , communi cate on the Chrysl er Col l i si on
Detecti on (CCD) data bus network through a sepa-
rate two-way wi re harness connector. The CCD data
bus network al l ows the shari ng of sensor i nforma-
ti on. Thi s hel ps to reduce wi re harness compl exi ty,
i nternal control l er hardware, and component sensor
current l oads. At the same ti me, thi s system provi des
i ncreased rel i abi l i ty, enhanced di agnosti cs, and
al l ows the addi ti on of many new feature capabi l i ti es.
I n addi ti on, radi os connected to the CCD data bus
have several audi o system functi ons that can be di ag-
nosed usi ng a DRB scan tool . Refer to the proper
Di agnosti c Procedures manual for more i nformati on
on DRB testi ng of the audi o systems.
The radi o can onl y be servi ced by an authori zed
radi o repai r stati on. Refer to the l atest Warranty Pol -
i ci es and Procedures manual for a current l i sti ng of
authori zed radi o repai r stati ons.
For more i nformati on on radi o features, setti ng
procedures, and control functi ons refer to the owners
manual i n the vehi cl e gl ove box.
RADIO IGNITION INTERFERENCE
I f recei vi ng i gni ti on/engi ne i nterference noi se on
the radi o stati ons, check and cl ean al l engi ne and
body ground connecti ons. Ti ghten properl y after
cl eani ng. Exampl e (Fi g. 1), (Fi g. 2), (Fi g. 3) and (Fi g.
4).
Ensure al l ground connecti ons are wi thout corro-
si on.
CHOKEINFINITY SPEAKERS
I f the audi o system i s l acki ng bass response, check
for conti nui ty across the choke connector. I f no conti -
nui ty Repl ace choke. The choke i s l ocated on the
Fig. 1 Motor Mount to Frame Rail Ground
Fig. 2 2.4L Engine Block Ground
Fig. 3 3.0L Engine Block Ground
Fig. 4 3.3/3.8L Engine Block Ground
8F - 2 AUDIO SYSTEMS NS
bracket behi nd the juncti on bl ock/body control mod-
ul e (Fi g. 5).
REMOTE RADIO SWITCHES
A remote radi o control swi tch opti on i s avai l abl e on
LXI model s sol d i n North Ameri ca wi th the AM/FM/
cassette/5-band graphi c equal i zer wi th CD changer
control feature (RBN sal es code), or the AM/FM/CD/
cassette/3-band graphi c equal i zer (RAZ sal es code)
radi o recei vers. Two rocker-type swi tches are
mounted on the back (i nstrument panel si de) of the
steeri ng wheel spokes. The swi tch on the l eft spoke i s
the seek swi tch and has seek up, seek down, and pre-
set stati on advance functi ons. The swi tch on the
ri ght spoke i s the vol ume control swi tch and has vol -
ume up, and vol ume down functi ons (Fi g. 6).
These swi tches are resi stor mul ti pl exed uni ts that
are hard-wi red to the Body Control Modul e (BCM)
through the cl ockspri ng. The BCM sends the proper
messages on the Chrysl er Col l i si on Detecti on (CCD)
data bus network to the radi o recei ver. For di agnosi s
of the BCM or the CCD data bus, the use of a DRB
scan tool and the proper Di agnosti c Procedures man-
ual are recommended. For more i nformati on on the
operati on of the remote radi o swi tch control s, refer to
the owners manual i n the vehi cl e gl ove box.
NAME BRAND SPEAKER RELAY
Rel ay i s l ocated i n the juncti on bl ock. To test rel ay
refer to the Audi o Di agnosti c Test Procedures or use
a known good rel ay.
ANTENNA
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
The fol l owi ng four tests are used to di agnose the
antenna wi th an ohmmeter:
Test 1 - Mast to ground test
Test 2 - Ti p-of-mast to ti p-of-conductor test
Test 3 - Body ground to battery ground test
Test 4 - Body ground to coaxi al shi el d test.
The ohmmeter test l ead connecti ons for each test
are shown i n Antenna Tests (Fi g. 7).
NOTE: This model has a two-piece antenna coaxial
cable. Tests 2 and 4 must be conducted in two
steps to isolate a coaxial cable problem; from the
coaxial cable connection under the right end of the
instrument panel near the right cowl side panel to
the antenna base, and then from the coaxial cable
connection to the radio chassis connection.
TEST 1
Test 1 determi nes i f the antenna mast i s i nsul ated
from the base. Proceed as fol l ows:
(1) Unpl ug the antenna coaxi al cabl e connector
from the radi o chassi s and i sol ate.
(2) Connect one ohmmeter test l ead to the ti p of
the antenna mast. Connect the other test l ead to the
antenna base. Check for conti nui ty.
(3) There shoul d be no conti nui ty. I f conti nui ty i s
found, repl ace the faul ty or damaged antenna base
and cabl e assembl y.
Fig. 5 Choke Location
Fig. 6 Remote Radio Switch Operational View
TEST 2
Test 2 checks the antenna for an open ci rcui t as
fol l ows:
(1) Unpl ug the antenna coaxi al cabl e connector
from the radi o chassi s.
(2) Connect one ohmmeter test l ead to the ti p of
the antenna mast. Connect the other test l ead to the
center pi n of the antenna coaxi al cabl e connector.
(3) Conti nui ty shoul d exi st (the ohmmeter shoul d
onl y regi ster a fracti on of an ohm). Hi gh or i nfi ni te
resi stance i ndi cates damage to the base and cabl e
assembl y. Repl ace the faul ty base and cabl e, i f
requi red.
TEST 3
Test 3 checks the condi ti on of the vehi cl e body
ground connecti on. Thi s test shoul d be performed
wi th the battery posi ti ve cabl e removed from the bat-
tery. Di sconnect both battery cabl es, the negati ve
cabl e fi rst. Reconnect the battery negati ve cabl e and
perform the test as fol l ows:
(1) Connect one ohmmeter test l ead to the vehi cl e
fender. Connect the other test l ead to the battery
negati ve post.
(2) The resi stance shoul d be l ess than (1) ohm.
(3) I f the resi stance i s more than (1) ohm, check
the brai ded ground strap connected to the engi ne and
the vehi cl e body for bei ng l oose, corroded, or dam-
aged. Repai r the ground strap connecti on, i f requi red.
TEST 4
Test 4 checks the condi ti on of the ground between
the antenna base and the vehi cl e body as fol l ows:
(1) Connect one ohmmeter test l ead to the vehi cl e
fender. Connect the other test l ead to the outer cri mp
on the antenna coaxi al cabl e connector.
(2) The resi stance shoul d be l ess then (1) ohm.
(3) I f the resi stance i s more then (1) ohm, cl ean
and/or ti ghten the antenna base to fender mounti ng
hardware.
AUDIO SYSTEM
INJURY.
RADIO
I f the vehi cl e i s equi pped wi th remote radi o
swi tches l ocated on the backs of the steeri ng wheel
spokes, and the probl em bei ng di agnosed i s rel ated to
one of the symptoms l i sted bel ow, be certai n to check
the remote radi o swi tches and ci rcui ts as descri bed
i n thi s group, pri or to attempti ng radi o di agnosi s or
repai r.
Stati ons changi ng wi th no remote radi o swi tch
i nput
Radi o memory presets not worki ng properl y
Vol ume changes wi th no remote radi o swi tch
i nput
Remote radi o swi tch buttons taki ng on other
functi ons
CD pl ayer ski ppi ng tracks
Remote radi o swi tch i noperati ve.
For ci rcui t descri pti ons and di agrams, refer to
Group 8W - Wi ri ng Di agrams.
INJURY.
CAUTION: The speaker output of the radio is a
floating ground system. Do not allow any speaker
lead to short to ground, as damage to the radio
may result.
Fig. 7 Antenna Tests
CONDITION POSSIBLE CAUSE CORRECTION
NO AUDIO. 1. FUSE FAULTY.
2. RADIO CONNECTOR
FAULTY.
3. WIRING FAULTY.
4. GROUND FAULTY.
5. RADIO FAULTY.
6. SPEAKERS FAULTY.
1. CHECK RADIO FUSES IN FUSEBLOCK MODULE.
REPLACE FUSES, IF REQUIRED.
2. CHECK FOR LOOSE OR CORRODED RADIO
CONNECTOR. REPAIR, IF REQUIRED.
3. CHECK FOR BATTERY VOLTAGE AT RADIO
CONNECTOR. REPAIR WIRING, IF REQUIRED.
4. CHECK FOR CONTINUITY BETWEEN RADIO CHASSIS
AND A KNOWN GOOD GROUND. THERE SHOULD BE
CONTINUITY. REPAIR GROUND, IF REQUIRED.
5. EXCHANGE OR REPLACE RADIO, IF REQUIRED.
6. SEE SPEAKER DIAGNOSIS, IN THIS GROUP.
NO DISPLAY. 1. FUSE FAULTY.
2. RADIO CONNECTOR
FAULTY.
3. WIRING FAULTY.
4. GROUND FAULTY.
5. RADIO FAULTY.
1. CHECK RADIO FUSES IN FUSEBLOCK MODULE.
REPLACE FUSES, IF REQUIRED.
NO MEMORY. 1. FUSE FAULTY.
2. RADIO CONNECTOR
FAULTY.
3. WIRING FAULTY.
4. GROUND FAULTY.
5. RADIO FAULTY.
1. CHECK IGNITION-OFF DRAW FUSE. REPLACE FUSE,
IF REQUIRED.
POOR RADIO
RECEPTION.
1. ANTENNA FAULTY.
2. GROUND FAULTY.
3. RADIO FAULTY.
1. SEE ANTENNA DIAGNOSIS, IN THIS GROUP. REPAIR
OR REPLACE ANTENNA, IF REQUIRED.
CONTINUITY. REPAIR GROUND, IF REQUIRED..
NO/POOR TAPE
OPERATION.
1. FAULTY TAPE.
2. FOREIGN OBJECTS
BEHIND TAPE DOOR.
3. DIRTY CASSETTE TAPE
HEAD.
4. FAULTY TAPE DECK.
1. INSERT KNOWN GOOD TAPE AND TEST OPERATION.
2. REMOVE FOREIGN OBJECTS AND TEST OPERATION.
3. CLEAN HEAD WITH MOPAR CASSETTE HEAD
CLEANER.
NO COMPACT
DISC
OPERATION
1. FAULTY CD.
2. FOREIGN MATERIAL ON
CD.
3. CONDENSATION ON CD
OR OPTICS.
4. FAULTY CD PLAYER.
1. INSERT KNOWN GOOD CD AND TEST OPERATION.
2. CLEAN CD AND TEST OPERATION.
3. ALLOW TEMPERATURE OF VEHICLE INTERIOR TO
STABILIZE AND TEST OPERATION.
AUDIO SYSTEM DIAGNOSIS
(1) Check the fuse(s) i n the juncti on bl ock and the
Power Di stri buti on Center (PDC). I f OK, go to Step
2. I f not OK, repai r the shorted ci rcui t or component
as requi red and repl ace the faul ty fuse(s).
(2) Check for battery vol tage at the fuse i n the
PDC. I f OK, go to Step 3. I f not OK, repai r the open
ci rcui t to the battery as requi red.
(3) Turn the i gni ti on swi tch to the ON posi ti on.
Check for battery vol tage at the fuse i n the juncti on
bl ock. I f OK, go to Step 4. I f not OK, repai r the open
ci rcui t to the i gni ti on swi tch as requi red.
(4) Turn the i gni ti on swi tch to the OFF posi ti on.
Di sconnect and i sol ate the battery negati ve cabl e.
Remove the i nstrument cl uster center bezel . Remove
the radi o, but do not unpl ug the wi re harness connec-
tors. Check for conti nui ty between the radi o chassi s
and a good ground. There shoul d be conti nui ty. I f
OK, go to Step 5. I f not OK, repai r the open radi o
chassi s ground ci rcui t as requi red.
(5) Connect the battery negati ve cabl e. Turn the
i gni ti on swi tch to the ON posi ti on. Check for battery
vol tage at the fused i gni ti on swi tch output ci rcui t
cavi ty of the l eft (gray) radi o wi re harness connector.
I f OK, go to Step 6. I f not OK, repai r the open ci rcui t
as requi red.
(6) Turn the i gni ti on swi tch to the OFF posi ti on.
Check for battery vol tage at the fused B(+) ci rcui t
cavi ty of the l eft (gray) radi o wi re harness connector.
I f OK, repl ace the faul ty radi o. I f not OK, repai r the
open ci rcui t to the I gni ti on-Off Draw (I OD) fuse as
requi red.
INJURY.
(1) Di sconnect and i sol ate the battery negati ve
cabl e. Wai t two mi nutes for the ai rbag system capac-
i tor to di scharge before further servi ce.
(2) Remove the remote radi o swi tch(es) from the
steeri ng wheel .
(3) Use an ohmmeter to check the swi tch resi s-
tance as shown i n the Remote Radi o Swi tch Test
tabl e (Fi g. 8).
NOTE: The right remote radio switch back is white
in color. The left switch back is black in color. The
right/left remote radio switch orientation is with the
steering wheel installed, and driver in drivers seat.
(4) I f the swi tch resi stance checks OK, go to Step
5. I f not OK, repl ace the faul ty swi tch.
(5) Check for conti nui ty between the ground ci r-
cui t cavi ty of the swi tch wi re harness connector and
a good ground. There shoul d be conti nui ty. I f OK, go
to Step 6. I f not OK, repai r the open ci rcui t as
requi red.
(6) Unpl ug the 24-way whi te wi re harness connec-
tor from the Body Control Modul e (BCM). Check for
conti nui ty between the radi o control ci rcui t cavi ty of
the remote radi o swi tch wi re harness connector and a
good ground. There shoul d be no conti nui ty. I f OK, go
to Step 7. I f not OK, repai r the short ci rcui t as
requi red.
(7) Check for conti nui ty between the radi o control
ci rcui t cavi ti es of the remote radi o swi tch wi re har-
ness connector and the BCM wi re harness connector.
There shoul d be conti nui ty. I f OK, refer to the proper
Di agnosti c Procedures manual to test the BCM and
the CCD data bus. I f not OK, repai r the open ci rcui t
as requi red.
Fig. 8 Remote Radio Switches
REMOTE RADIO SWITCH TEST
SWITCH POSITION RESISTANCE
VOLUME UP 7320 OHMS
VOLUME DOWN 1210 OHMS
SEEK UP 4530 OHMS
SEEK DOWN 2050 OHMS
PRE-SET STATION ADVANCE 10 OHMS
ANTENNA MAST AND CABLE LEAD
REMOVAL
(1) Remove gl ove box from i nstrument panel , refer
to Group 8E, I nstrument Panel and Systems for
proper procedures.
(2) Di sconnect antenna cabl e connector from exten-
si on cabl e (Fi g. 9).
(3) Remove ri ght ki ck tri m panel .
(4) Di sengage rubber grommet i nsul ator from door
hi nge pi l l ar.
(5) Pul l antenna cabl e through hi nge pi l l ar i nto
open between door hi nges.
(7) Remove front wheel , refer to Group 22, Wheel
and Tri es for proper procedures and ti ghteni ng refer-
ences.
(8) Remove front wheel house spl ash shi el d, refer
to Group 23, Body for proper procedures.
(9) Sl i de the pl asti c sl eeve up on antenna mast for
access to mast. Remove antenna mast from antenna
base (Fi g. 10).
(10) Remove pl asti c cap from the cap nut. Usi ng
cap nut tool , remove cap nut hol di ng antenna base to
front fender (Fi g. 11).
(11) Remove antenna base from under front fender.
INSTALLATION
ANTENNA EXTENSION CABLE
REMOVAL
(2) Di sconnect extensi on cabl e end from antenna
cabl e end (Fi g. 9).
(3) Di sconnect cabl e hanger cl i p from HVAC uni t.
(4) Remove radi o as necessary to gai n access to
extensi on cabl e.
(5) Di sconnect extensi on cabl e from back of radi o.
(6) Remove extensi on cabl e from vehi cl e.
INSTALLATION
Fig. 9 Antenna Cable
Fig. 10 Antenna Mast
RADIO/TAPE/CD PLAYER
REMOVAL
(1) Remove HVAC swi tch bezel , refer to Group 8E,
I nstrument Panel and Systems for proper procedure.
(2) Remove screws hol di ng radi o to i nstrument
panel (Fi g. 12).
(3) Pul l radi o rearward to gai n access to back of
radi o (Fi g. 13).
(4) Remove bol t hol di ng ground strap to back of
radi o.
(5) Di sconnect antenna cabl e from back of radi o.
radi o.
(7) Remove radi o from vehi cl e.
INSTALLATION
INSTRUMENT PANEL SPEAKER
INSTALLATION
(1) Remove i nstrument panel top cover.
(2) Remove screws hol di ng speaker to i nstrument
panel and remove speaker (Fi g. 14) or (Fi g. 15).
(3) Remove anti rocki ng fi nger screw.
(4) Di sconnect wi re connector from speaker.
(5) Remove speaker.
INSTALLATION
Fig. 11 Antenna Cap Nut
Fig. 12 Radio
Fig. 13 Radio Connectors
Fig. 14 Left Instrument Panel Speaker
FRONT DOOR SPEAKER
REMOVAL
(1) Remove front door tri m panel as necessary to
gai n access to door speaker. Refer to Group 23, Body
for proper procedures.
(2) Remove screws hol di ng speaker to bracket (Fi g.
16).
(3) Remove speaker from bracket.
(5) Remove speaker.
INSTALLATION
INJURY.
REMOVAL
cabl e. Wai t two mi nutes for the ai rbag system capac-
i tor to di scharge before further servi ce.
(2) From the undersi de of the steeri ng wheel ,
remove the (3) bol ts that secure the dri ver si de ai r-
bag modul e to the steeri ng wheel .
(3) Pul l the ai rbag modul e away from the steeri ng
wheel far enough to access the wi re harness connec-
tors on the back of the ai rbag modul e.
(4) Unpl ug the ai rbag modul e and horn swi tch
wi re harness connectors from the back of the ai rbag
modul e.
(5) Remove the dri ver si de ai rbag modul e from the
vehi cl e.
(6) Remove the steeri ng wheel from the steeri ng
col umn. Refer to Group 19Steeri ng, for servi ce pro-
cedure.
(7) Unpl ug the wi re harness connector from the
remote radi o swi tch (s).
(8) Remove three screws securi ng steeri ng wheel
rear cover. Refer to Group 19, Steeri ng for seri vce
procedure.
(9) Remove the remote radi o swi tch from the steer-
i ng wheel by depressi ng tabs on each si de of swi tch..
NOTE: The right remote radio switch back is white
in color. The left switch back is black in color. The
right/left remote radio switch orientation is with the
steering wheel installed, and driver in drivers seat.
INSTALLATION
For i nstal l ati on, reverse the above procedure. The
swi tches can onl y be i nstal l ed one way. Be careful to
i ndex them correctl y before pressi ng them i nto pl ace.
Ti ghten the ai rbag modul e mounti ng screws to 10.2
Nm (90 i n. l bs.).
Fig. 15 Right Instrument Panel Speaker
Fig. 16 Front Door Speaker
QUARTER PANEL SPEAKER
REMOVAL
(1) Remove quarter tri m bol ster from quarter tri m
panel .
(2) Remove screws hol di ng speaker to i nner quar-
ter panel (Fi g. 17).
(3) Separate speaker from quarter panel .
(5) Remove speaker.
INSTALLATION
DPILLAR SPEAKER
REMOVAL
(1) Remove D-pi l l ar tri m panel as necessary to
gai n access to door speaker. Refer to Group 23, Body
for proper procedures.
(3) Remove by sl i di ng speaker out of bracket by
pushi ng on magnet. The capaci tor i s wrapped wi th
foam tape (Fi g. 18).
(4) Remove speaker.
INSTALLATION
Fig. 17 Quarter Panel Speaker
Fig. 18 DPillar Speaker
HORNS
CONTENTS
page page
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . 1
HORN RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
HORN SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . 3
HORN SYSTEM TEST . . . . . . . . . . . . . . . . . . . . . 3
HORN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
HORNS SOUND CONTINUOUSLY . . . . . . . . . . . . 3
HORNS WILL NOT SOUND . . . . . . . . . . . . . . . . 2
HORN SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . 4
HORNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
INTRODUCTION
BAG, SEE GROUP 8M, RESTRAINT SYSTEMS FOR
SAFETY PRECAUTIONS. DISCONNECT THE NEGA-
TIVE CABLE FROM THE BATTERY BEFORE SER-
VICING COMPONENTS INVOLVING THE AIRBAG
SYSTEM. ACCIDENTAL DEPLOYMENT OF AIRBAG
AND PERSONAL INJURY CAN RESULT.
The horn ci rcui t consi sts of a horn swi tch, cl ock-
spri ng, horn rel ay, horns and Body Control Modul e
(Fi g. 1). The horn swi tch i s a membrane swi tch
l ocated i n the ai rbag cover. The horns are l ocated for-
ward of the l eft front wheel behi nd the bumper fas-
ci a. The horn rel ay pl ugs i nto the juncti on bl ock. For
ci rcui t i nformati on and component l ocati ons refer to
Group 8W, Wi ri ng Di agrams.
HORN
(1) Di sconnect wi re connector at horn.
(2) Usi ng a vol tmeter, connect one l ead to ground
termi nal and the other l ead to the posi ti ve wi re ter-
mi nal (Fi g. 3).
(3) Depress the horn swi tch, battery vol tage
shoul d be present.
(4) I f no vol tage, refer to Horn Wi l l Not Sound. I f
vol tage i s OK, go to step Step 5.
(5) Usi ng ohmmeter, test ground wi re for conti nu-
i ty to ground.
(6) I f no ground repai r as necessary.
(7) I f wi res test OK and horn does not sound,
repl ace horn.
HORN RELAY
(1) Remove horn rel ay.
(2) Usi ng ohmmeter, test between rel ay connector
termi nal s 85 to 86 for 70 to 75 ohms resi stance (Fi g.
2). I f resi stance not OK, repl ace rel ay.
(3) Test for conti nui ty between ground and termi -
nal 85 of horn rel ay.
(a) When the horn swi tch i s not depressed, no
conti nui ty shoul d be present.
(b) Conti nui ty to ground when horn swi tch i s
depressed.
(c) I f conti nui ty i s not correct repai r horn
swi tch or wi ri ng as necessary, refer to Group 8W,
Wi ri ng Di agrams Group 8M Restrai nt System for
Dri vers Ai rbag Modul e removal procedures.
(4) Usi ng vol tmeter, test vol tage at:
(a) Termi nal s 30 and 86 of the horn rel ay to
body ground.
(b) I f NO vol tage check fuse 7 of the BCM.
(c) I f i ncorrect vol tage repai r as necessary. Refer
to Group 8W, Wi ri ng Di agrams.
(5) I nsert a jumper wi re between termi nal 30 and
87 of the power di stri buti on center.
(a) I f horn sounds repl ace rel ay.
Fig. 1 Horn System
NS HORNS 8G - 1
(b) I f the horn does not sound, i nstal l horn rel ay
and refer to Horn Test.
HORNS WILL NOT SOUND
Check horn fuse 6 i n the Power Di stri buti on Cen-
ter and fuse 7 i n the Juncti on Bl ock. I f fuse i s bl own
refer to FUSE BLOWN secti on. I f fuse i s OK, refer to
FUSE OK secti on.
FUSE BLOWN
(1) Veri fy condi ti on of battery termi nal s and vol t-
age, refer to Group 8A, Battery. I f battery connec-
ti ons and battery charge i s OK proceed to Step 2.
(2) Usi ng a vol tmeter, test for battery vol tage at
both si des of horn fuse 7. I f vol tage i s OK, on both
si des of fuse, proceed to Fuse OK. I f vol tage i s OK,
on one si de of fuse, the fuse i s bl own, proceed to Step
3.
(3) Usi ng a sui tabl e ammeter i n pl ace of the fuse,
test amperage draw of the horn ci rcui t. I f amperage
draw i s greater than 20 amps wi thout the horn
swi tch depressed, a grounded ci rcui t exi sts between
the fuse and the horn rel ay. Proceed to Step 4. I f
amperage draw i s greater than 20 amps wi th the
horn swi tch depressed, a grounded ci rcui t exi sts
between the horn rel ay and the horn. Proceed to step
Step 5.
(4) Remove the horn rel ay from the Juncti on
Bl ock. I f the amperage draw drops to 0 amps, the
horn swi tch or ci rcui t i s shorted. Refer to group 8W,
Wi ri ng Di agrams for ci rcui t i nformati on. I f the
amperage draw does not drop to 0 amps, repai r short
at the Juncti on Bl ock.
(5) Di sengage a wi re connector from one of the
horns. I f amperage drops and the connected horn
sounds, repl ace the faul ty horn. I f amperage does not
drop wi th both horns di sconnected and the horn
swi tch depressed, proceed to Step 6.
(6) Usi ng a conti nui ty tester, wi th the horns di s-
connected test conti nui ty of the X2 cavi ty of the horn
rel ay to ground. Refer to Group 8W, Wi ri ng Di agrams
for ci rcui t i nformati on. I f conti nui ty i s detected, the
ci rcui t i s grounded between the Juncti on Bl ock and
the horns. Locate and repai r pi nched harness.
FUSE OK
(1) Remove the horn rel ay from the Juncti on
Bl ock.
(2) Usi ng a conti nui ty tester, Depress horn swi tch
and test conti nui ty from the X3 cavi ty of the horn
rel ay to ground. Refer to Group 8W, Wi ri ng Di agrams
for ci rcui t i nformati on.
(a) I f conti nui ty i s detected, proceed to Step 3.
(b) I f NO conti nui ty, proceed to Step 4.
(3) Usi ng a sui tabl e jumper wi re, jump across the
fuse F62 cavi ty and the X2 cavi ty of the horn rel ay i n
the Juncti on Bl ock.
(a) I f the horn sounds, repl ace the horn rel ay.
(b) I f the horn does not sound, proceed to Step 4.
(4) Remove ai rbag/horn pad from steeri ng wheel .
Refer to Group 8M, Restrai nt Systems for proper pro-
cedures.
(5) Test conti nui ty across horn swi tch connectors
wi th horn swi tch depressed.
(a) I f conti nui ty i s detected, repai r open ci rcui t
between the rel ay and the horn swi tch.
(b) I f NO conti nui ty, repl ace ai rbag cover.
(6) I nstal l horn rel ay i nto Juncti on Bl ock.
(7) Di sengage wi re connectors from horns.
(8) Usi ng a vol tmeter, wi th the horn swi tch
depressed test vol tage across horn connector termi -
nal s of the wi re harness (Fi g. 3).
(a) I f vol tage i s detected, repl ace horns.
(b) I f NO vol tage, proceed to step Step 9.
(9) Wi th the horn swi tch depressed, test for vol t-
age between the X2 ci rcui t and ground.
(a) I f vol tage OK, repai r system ground at ri ght
cowl area. Refer to Group 8W, Wi ri ng Di agrams.
(b) I f NO vol tage, repai r open X2 ci rcui t between
the rel ay and the horns.
Fig. 2 Horn Relay
Fig. 3 Horn and Connector
8G - 2 HORNS NS
HORNS SOUND CONTINUOUSLY
CAUTION: Continuous sounding of horns may
cause relay to fail.
The horn swi tch (membrane) someti mes can be the
cause wi thout the swi tch bei ng depressi ng.
(1) Remove the horn rel ay from the juncti on bl ock.
(2) Usi ng a conti nui ty tester, test conti nui ty from
the X3 cavi ty of the horn rel ay to ground. Refer to
Group 8W, Wi ri ng Di agrams for ci rcui t i nformati on.
(a) I f conti nui ty i s detected, proceed to step Step
3.
(b) I f NO conti nui ty, repl ace the horn rel ay.
(3) Remove the ai rbag/horn pad from the steeri ng
wheel and di sengage horn connector.
(4) I nstal l horn rel ay i nto juncti on bl ock.
(a) I f horn does not sound, repl ace ai rbag cover/
horn pad.
(b) I f horn sounds, repai r grounded X3 ci rcui t
from juncti on bl ock to cl ockspri ng i n steeri ng i n
steeri ng col umn. Refer to Group 8W, Wi ri ng Di a-
grams.
HORN SYSTEM
Refer to Horn System Test bel ow. I f the horn does
not sound, check horn fuse l ocated i n the Power Di s-
tri buti on Center. I f the fuse i s bl own, repl ace wi th
the correct fuse. I f the horn fai l to sound and the
new fuse bl ows when depressi ng the horn swi tch, a
short ci rcui t i n the horn or the horn wi ri ng between
the fuse termi nal and the horn i s responsi bl e, or a
defecti ve horn swi tch al l owed the horn to burn out i s
responsi bl e.
I f the fuse i s OK, test horn rel ay refer to Horn
Rel ay Test.
I f the rel ay i s OK, test horn. Refer to Horn System
Test.
CAUTION: Continuous sounding of horn may
cause horn relay to fail.
Shoul d the horn sound conti nuousl y:
Unpl ug the horn rel ay from Power Di stri buti on
Center.
Refer to Horn Rel ay Test.
Refer to Group 8W, Wi ri ng Di agrams for ci rcui t
and wi ri ng i nformati on.
HORN SYSTEM TEST
Horn sounds continuously.
NOTE: Immediately unplug horn
relay in the Power Distribution
Center (PDC)
(1) Faulty horn relay.
(2) Horn control circuit to relay
shorted to ground.
(3) Pinched horn switch wire under
Driver Airbag Module.
(4) Defective horn switch
(1) Refer to horn relay test.
(2) Check terminal 85 in Junction
Block for continuity to ground. If
continuity to ground indicates:
(a) Steering Wheel horn switch/lead
shorted to ground.
(b) Wiring harness shorted to
ground. Find the short and repair as
necessary.
(3) Replace Driver Airbag Module.
Horn sound intermittently as the
steering wheel is turned.
(1) Horn relay control circuit X3 is
shorted to ground inside steering
column or wheel.
(2) Pinched horn switch wire under
Driver Airbag Module
(1) Remove Driver Airbag Module
and/or wheel. Check for rubbing or
loose wire/connector, repair as
necessary.
Horn does not sound (1) Check fuse 6 in PDC
(2) No Voltage at horn relay
terminals 30 & 86, and fuse is OK.
(3) Open circuit from terminal 85 of
the horn relay to horn switch, X3
circuit.
(4) Defective or damaged horn.
(1) Replace fuse if blown repair as
necessary.
(2) No voltage, repair the A6 circuit
as necessary.
(3) Repair circuit as necessary.
(4) Voltage at horn when horn switch
is pressed, replace horn.
NS HORNS 8G - 3
Fuse blows when horn sounds (1) Short circuit in horn or horn
wiring
(1) Remove horn relay, check for
shorted horn or horn wiring.
Disconnect horn wire harness to
isolate short and repair as
necessary.
Fuse blows without blowing horn (1) Short circuit (1) Remove relay, install new fuse, if
fuse does not blow replace horn
relay. If fuse blows with relay
removed, check for short to ground
with ohmmeter on circuit between
terminals 30 & 86 and the fuse
terminal. Repair as necessary.
NOTE: For wiring repairs refer to
Group 8W, Wire Diagrams.
HORN SWITCH
The horn swi tch i s mol ded i nto the ai rbag cover.
The horn swi tch cannot be servi ced separatel y. Refer
to Group 8M, Restrai nt System for Dri ver Ai rbag
Modul e Removal and I nstal l ati on procedures.
HORNS
REMOVAL
(1) Hoi st and support the front of the vehi cl e on
safety stands.
(2) From behi nd the front fasci a and forward of
the l eft front wheel , di sconnect the wi re connectors
from horn.
(3) Remove the mount bracket attachi ng nut from
the bottom of radi ator cl osure panel . Do not remove
the horn from mounti ng bracket (Fi g. 4).
(4) Separate the horn from vehi cl e.
INSTALLATION
For i nstal l ati on reverse the above procedures.
Fig. 4 Horn Removal/Installation
8G - 4 HORNS NS
VEHICLE SPEED CONTROL SYSTEM
CONTENTS
page page
GENERAL INFORMATION
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . 1
AUTOMATIC SPEED CONTROL OVERSPEED
REDUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SERVO CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SPEED CONTROL SERVO. . . . . . . . . . . . . . . . . . 1
SPEED CONTROL SWITCHES . . . . . . . . . . . . . . 1
STOP LAMP SWITCH . . . . . . . . . . . . . . . . . . . . . 2
VACUUM RESERVOIR . . . . . . . . . . . . . . . . . . . . 3
VEHICLE SPEED AND DISTANCE . . . . . . . . . . . . 3
CHECKING FOR DIAGNOSTIC CODES . . . . . . . . 3
ELECTRICAL TESTS AT POWERTRAIN
CONTROL MODULE . . . . . . . . . . . . . . . . . . . . . 6
OVERSHOOT/UNDERSHOOT FOLLOWING
SPEED CONTROL SET . . . . . . . . . . . . . . . . . . . 3
ROAD TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVO VACUUM TEST . . . . . . . . . . . . . . . . . . . . 6
SPEED CONTROL ELECTRICAL TEST . . . . . . . . 4
SPEED CONTROL SWITCH TEST . . . . . . . . . . . . 6
STOP LAMP SWITCH TEST . . . . . . . . . . . . . . . . 6
VACUUM SUPPLY TEST . . . . . . . . . . . . . . . . . . . 8
VEHICLE SPEED SENSOR . . . . . . . . . . . . . . . . . 8
SPEED CONTROL CABLE . . . . . . . . . . . . . . . . . . 9
SPEED CONTROL SERVO. . . . . . . . . . . . . . . . . . 8
SPEED CONTROL SWITCHES . . . . . . . . . . . . . . 9
STOP LAMP SWITCH . . . . . . . . . . . . . . . . . . . . 9
VACUUM RESEROIR . . . . . . . . . . . . . . . . . . . . . 10
VEHICLE SPEED SENSOR . . . . . . . . . . . . . . . . 10
GENERAL INFORMATION
INTRODUCTION
The speed control system i s el ectroni cal l y con-
trol l ed and vacuum operated. The el ectroni c control
i s i ntegrated i nto the powertrai n control modul e,
l ocated next to battery. The control s are l ocated on
the steeri ng wheel and consi st of the ON/OFF, SET,
RESUME/ACCEL, CANCEL and DECEL buttons
(Fi g. 1).
SPEED CONTROL SERVO
The servo uni t consi sts of a sol enoi d val ve body,
and a vacuum chamber. The PCM control s the sol e-
noi d val ve body. The sol enoi d val ve body control s the
appl i cati on and rel ease of vacuum to the di aphragm
of the vacuum servo. The servo uni t cannot be
repai red and i s servi ced onl y as a compl ete assembl y.
SPEED CONTROL SWITCHES
There are two separate swi tch pods that operate
the speed control system. The steeri ng-wheel -
mounted swi tches use mul ti pl exed ci rcui ts to provi de
i nputs to the PCM for ON, OFF, RESUME, ACCEL-
ERATE, SET, DECEL and CANCEL modes. Refer to
the owners manual for more i nformati on on speed
control swi tch functi ons and setti ng procedures.
When speed control i s sel ected by depressi ng the
ON swi tch, the PCM al l ows a set speed to be stored
i n RAM for speed control . To store a set speed,
depress the SET swi tch whi l e the vehi cl e i s movi ng
at a speed between 30 and 85 mph. I n order for the
speed control to engage, the brakes cannot be
appl i ed, nor can the gear sel ector be i ndi cati ng the
transmi ssi on i s i n Park or Neutral .
The speed control can be di sengaged manual l y by:
Steppi ng on the brake pedal
Fig. 1 Speed Control Switches
NS VEHICLE SPEED CONTROL SYSTEM 8H - 1
Depressi ng the OFF swi tch
Depressi ng the CANCEL swi tch.
NOTE: Depressing the OFF switch or turning off
the ignition switch will erase the set speed stored
in the PCM.
For added safety,the speed control system i s pro-
grammed to di sengaged for any of the fol l owi ng con-
di ti ons:
An i ndi cati on of Park or Neutral
An rpm i ncrease wi thout a VSS si gnal i ncrease
(i ndi cates that the cl utch has been di sengaged)
Excessi ve engi ne rpm (i ndi cates that the trans-
mi ssi on may be i n a l ow gear)
The VSS si gnal i ncreases at a rate of 10 mph
per second (i ndi cates that the co-effi ci ent of fri cti on
between the road surface and ti res i s extremel y l ow)
The VSS si gnal decreases at a rate of 10 mph
per second (i ndi cates that the vehi cl e may have
decel erated at an extremel y hi gh rate)
I f the actual speed i s not wi thi n 20 mph of the
set speed
The previ ous di sengagement condi ti ons are pro-
grammed for added safety.
Once the speed control has been di sengaged,
depressi ng the ACCEL swi tch when speed i s greater
than 25 mph restores the vehi cl e to the target speed
that was stored i n the PCM.
NOTE: Depressing the OFF switch will erase the
set speed stored in the PCMs RAM.
Whi l e the speed control i s engaged, the dri ver can
i ncrease the vehi cl e speed by depressi ng the ACCEL
swi tch. The new target speed i s stored i n the PCM
when the ACCEL i s rel eased. The PCM al so has a
tap-up feature i n whi ch vehi cl e speed i ncreases at a
rate of approxi matel y 2 mph for each momentary
swi tch acti vati on of the ACCEL swi tch. The PCM
al so provi des a means to decel erate wi thout di sen-
gagi ng speed control . To decel erate from an exi sti ng
recorded target speed, depress and hol d the COAST
swi tch unti l the desi red speed i s reached, then
rel ease the swi tch.
The i ndi vi dual swi tches cannot be repai red. I f one
swi tch fai l s, the enti re swi tch modul e must be
repl aced.
AUTOMATIC SPEED CONTROL OVERSPEED
REDUCTION
Transmi ssi on control software i ncl udes an auto-
mati c speed control overspeed reducti on feature. Thi s
mai ntai ns vehi cl e speed at the sel ected set poi nt
when descendi ng a grade.
The Transmi ssi on Control Modul e (TCM) fi rst
senses that the speed control i s set. I f the set speed
i s exceeded by more than 4 mph (6.5 km/hr) and the
throttl e i s cl osed, the TCM causes the transaxl e to
downshi ft to THI RD gear. After downshi fti ng, the
automati c speed control resumes normal operati on.
To ensure that an upshi ft i s appropri ate after the set
speed i s reached, the TCM wai ts unti l the speed con-
trol system opens the throttl e at l east 8 degrees
before upshi fti ng to OVERDRI VE agai n.
I f the dri ver appl i es the brakes, cancel i ng auto-
mati c speed control operati on wi th the transaxl e sti l l
i n THI RD gear, the TCM mai ntai ns thi s gear unti l
the dri ver opens the throttl e at l east 8 degrees to
avoi d an i nappropri ate upshi ft. The upshi ft i s al so
del ayed for 0.5 seconds after reachi ng the 8 degrees
throttl e openi ng i n anti ci pati on that the dri ver mi ght
open the throttl e enough to requi re THI RD gear.
Thi s wi l l avoi d unnecessary and di sturbi ng transmi s-
si on cycl i ng. I f the automati c speed control RESUME
feature i s used after braki ng, the upshi ft i s del ayed
unti l the set speed i s achi eved to reduce cycl i ng and
provi de better response.
STOP LAMP SWITCH
Vehi cl es equi pped wi th the speed control opti on use
a dual functi on stop l amp swi tch. The swi tch i s
mounted on the brake pedal mounti ng bracket under
the i nstrument panel . The PCM moni tors the state of
the dual functi on stop l amp swi tch. Refer to Group 5,
Brakes for more i nformati on on stop l amp swi tch ser-
vi ce and adjustment procedures.
SERVO CABLE
The speed control servo cabl e i s connected between
the speed control vacuum servo di aphragm and the
throttl e body control l i nkage. Thi s cabl e causes the
throttl e control l i nkage to open or cl ose the throttl e
val ve i n response to movement of the vacuum servo
di aphragm.
The speed control el ectroni c control ci rcui try i s
i ntegrated i nto the Powertrai n Control Modul e
(PCM). The PCM i s l ocated i n the engi ne compart-
ment. The PCM speed control functi ons are moni -
tored by the On-Board Di agnosti cs (OBD). Al l OBD-
sensed systems are moni tored by the PCM. Each
moni tored ci rcui t i s assi gned a Di agnosti c Troubl e
Code (DTC). The PCM wi l l store a DTC i n el ectroni c
memory for any fai l ure i t detects. See On-Board
Di agnosti c Tests i n thi s group for more i nformati on.
The PCM cannot be repai red and must be repl aced i f
faul ty.
USE THE DRB SCAN TOOL TO REPROGRAM
THE NEW PCM WITH THE VEHICLES ORIGI-
NAL IDENTIFICATION NUMBER (VIN) AND
THE ORGINAL VEHICLES MILAGE. IF THIS
8H - 2 VEHICLE SPEED CONTROL SYSTEM NS
STEP IS NOT DONE A DIAGONSTIC TROUBLE
CODE (DTC) MAY BE SET.
VACUUM RESERVOIR
The reservoi r contai ns a one-way check val ve to
trap engi ne vacuum i n the reservoi r. When engi ne
vacuum drops, as i n cl i mbi ng a grade whi l e dri vi ng,
the reservoi r suppl i es the vacuum needed to mai n-
tai n proper speed control operati on. The vacuum res-
ervoi r cannot be repai red and must be repl aced i f
faul ty.
VEHICLE SPEED AND DISTANCE
The 4 speed automati c Transmi ssi on Control Mod-
ul e (TCM) suppl i es the speed i nput to the PCM. The
PCM determi nes accel erati on rates. The speed con-
trol software i n the PCM uses vehi cl e speed and
accel erati on to control to the set speed.
Vehi cl es wi th a 3 speed automati c or manual trans-
mi ssi on have a vehi cl e speed sensor (VSS) mounted
to an adapter near the transmi ssi on output shaft.
The sensor i s dri ven through the adapter by a speed-
ometer pi ni on gear. The VSS pul se si gnal i s moni -
tored by the PCM to determi ne vehi cl e speed and to
mai ntai n speed control set speed. Refer to the appro-
pri ate Powertrai n Di agnosti c Procedures manual for
di agnosi s and testi ng of thi s component. Refer to
group 14, Fuel System for Removal /I nstal l ati on
ROAD TEST
Perform a vehi cl e road test to veri fy reports of
speed control system mal functi on. The road test
shoul d i ncl ude attenti on to the speedometer. Speed-
ometer operati on shoul d be smooth and wi thout fl ut-
ter at al l speeds.
Fl utter i n the speedometer i ndi cates a probl em
whi ch mi ght cause surgi ng i n the speed control sys-
tem. The cause of any speedometer probl ems shoul d
be corrected before proceedi ng. Refer to Group 8E,
I nstrument Panel and Gauges for speedometer di ag-
nosi s.
I f a road test veri fi es a surge fol l owi ng a set and
the speedometer operates properl y see Overshoot/
Undershoot on speed control set.
I f a road test veri fi es an i noperati ve system, and
the speedometer operates properl y, check for:
A Di agnosti c Troubl e Code (DTC). I f a DTC
exi sts, conduct tests per the Powertrai n Di agnosti c
Procedures servi ce manual .
A mi sadjusted brake (stop) l amp swi tch. Thi s
coul d al so cause an i ntermi ttent probl em.
Loose or corroded el ectri cal connecti ons at the
servo. Corrosi on shoul d be removed from el ectri cal
termi nal s and a l i ght coati ng of Mopar Mul ti purpose
Grease, or equi val ent, appl i ed.
Leaki ng vacuum reservoi r.
Loose or l eaki ng vacuum hoses or connecti ons.
Defecti ve one-way vacuum check val ve.
Secure attachment at both ends of the speed
control servo cabl e.
Smooth operati on of throttl e l i nkage and throttl e
body ai r val ve.
Conduct el ectri cal test at PCM.
Fai l ed speed control servo. Do the servo vacuum
test.
CAUTION: When test probing for voltage or conti-
nuity at electrical connectors, care must be taken
not to damage connector, terminals or seals. If
these components are damaged, intermittent or
complete system failure may occur.
OVERSHOOT/UNDERSHOOT FOLLOWING SPEED
CONTROL SET
I f the operator repeatedl y presses and rel eases the
set button wi th thei r foot off of the accel erator (a l i ft
foot set to begi n speed control operati on), the vehi cl e
may accel erate and exceed the desi red set speed by
up to 5 MPH (8 km/h) and then decel erate to l ess
than the desi red set speed before fi nal l y achi evi ng
the desi red set speed.
The Speed Control has an adapti ve strategy that
compensates for vehi cl e-to-vehi cl e vari ati ons i n speed
control cabl e l engths. When the speed control i s set
wi th the vehi cl e operators foot off of the accel erator
pedal , the speed control thi nks there i s excessi ve
speed control cabl e sl ack and adapts. I f the l i ft foot
sets are conti nual l y used, the speed control over-
shoot/undershoot condi ti on wi l l devel op.
To unl earn the overshoot/undershoot condi ti on,
the vehi cl e operator has to press and rel ease the set
button whi l e mai ntai ni ng the desi red set speed wi th
the accel erator pedal (not decel erati ng or accel erat-
i ng), and then turn the crui se control swi tch to the
OFF posi ti on (or press the CANCEL button i f
equi pped) after wai ti ng 10 seconds. Thi s procedure
must be performed approxi matel y 1015 ti mes to
compl etel y unl earn the overshoot/undershoot condi -
ti on.
CHECKING FOR DIAGNOSTIC CODES
When tryi ng to veri fy a speed control system el ec-
troni c mal functi on: Connect a DRB scan tool i f avai l -
abl e to the data l i nk connector. The connector i s
l ocated at l eft si de of the steeri ng col umn, and at
l ower edge of the panel .
(1) A speed control mal functi on may occur wi thout
a di agnosti c code bei ng i ndi cated.
Refer to Group 25, for further i nformati on and use-
age of the DRB scan tool and a more compl ete l i st of
Di agnosti c Troubl e Code.
SPEED CONTROL SLOWS DOWN BY ITSELF
Test vehi cl e speed sensor, refer to group 8E. I f sen-
sor fai l s repl ace sensor, i f i t passes perform the fol -
l owi ng test:
(1) Perform the speed control swi tch test on the
DECEL swi tch, i f i t fai l s repl ace swi tch.
(2) I f the swi tch passes, conduct the vacuum sup-
pl y test.
(3) I f i t passes, conduct the servo vacuum test. I f i t
fai l s repl ace servo.
(4) I f conti nui ty, repl ace the PCM.
SPEED CONTROL ELECTRICAL TEST
El ectroni c speed control systems may be tested
usi ng two di fferent methods. One i nvol ves use of a
DRB. I f thi s test method i s desi red, refer to the Pow-
ertrai n Di agnosti c Test Procedures for chargi ng and
speed control system manual .
The other test method uses a vol t/ohm meter. The
vol t/ohm meter method i s descri bed i n the fol l owi ng
tests.
I f any i nformati on i s needed concerni ng wi ri ng,
refer to Group 8W, Wi ri ng Di agrams (Fi g. 2).
CAUTION: When test probing for voltage or conti-
nuity at electrical connectors, care must be taken
not to damage connector, terminals, or seals. If
these components are damaged, intermittent or
complete system failure may occur.
When el ectri cal connecti ons are removed, corrosi on
shoul d be removed from el ectri cal termi nal s and a
l i ght coati ng of Mopar Mul ti -Purpose Grease, or
equi val ent, appl i ed. I nspect connectors for damage
termi nal s.
A poor connecti on can cause a compl ete or i nter-
mi ttent mal functi on and i s al so the onl y connecti on
i n the ci rcui t, that can not be tested. For thi s reason,
a l oose connecti on may be mi sdi agnosed as a compo-
nent mal functi on.
SPEED CONTROL DIAGNOSTIC TROUBLE CODES
Hex Code DRB Scan Tool Display Description of Diagnostic Trouble
Code
23 No Vehicle Speed Sensor Signal No vehicle distance (speed) sensor
signal detected during road load
conditions.
OF Speed Control Solenoid Circuits An open or shorted condition
detected in the Speed Control
vacuum or vent solenoid circuits.
56 MUX S/C Switch High Speed Control switch input above
the maximum acceptable voltage.
57 MUX S/C Switch Low Speed Control switch input below
the minimum acceptable voltage.
52 S/C Power Relay Or 12V Driver
Circuit
Malfunction detected with power
feed to speed control servo solnoids.
Check Engine Lamp will illuminate during engine operation if this Diagnostic Trouble Code was recorded.
Fig. 2 Speed Control Circuit
SERVO VACUUM TEST
(1) Turn i gni ti on swi tch to the ON posi ti on wi th-
out starti ng engi ne. Acti vate speed control ON
swi tch.
(2) Di sconnect the four-way el ectri cal connector
and the vacuum harness at the servo (Fi g. 3).
(3) Connect a jumper wi re from Pi n 3 of the servo
to Pi n 3 of the wi re connector.
(4) Ground Pi ns 2 and 4 i n the servo. Do not con-
nect pi n 1.
(5) Connect a hand hel d vacuum pump to the vac-
uum ni ppl e and appl y 10 - 15 i nches of vacuum.
(6) I f servo pul l s cabl e, repl ace servo.
(7) Ground Pi n 1 on servo.
(8) Check that the throttl e cabl e pul l s i n and hol ds
as l ong as the vacuum pump i s connected. After one
mi nute, check i f cabl e i s sti l l hol di ng. I f cabl e does
not hol d repl ace the servo.
(9) Di sconnect jumper from pi n 3. Cabl e shoul d
return to rest posi ti on. I f not, repl ace servo.
(10) Connect 4 way el ectri cal connector and vac-
uum harness to servo.
SPEED CONTROL SWITCH TEST
Refer to the appropri ate Powertrai n Di agnosti c
Manual for swi tch test val ves.
STOP LAMP SWITCH TEST
(1) Remove the stop l amp swi tch refer to Stop
Swi tch Removal /I nstal l ati on i n thi s secti on. Di scon-
nect connector from stop l amp swi tch (Fi g. 4). Usi ng
an ohmmeter, swi tch conti nui ty may be checked as
fol l ows:
(2) Wi th swi tch pl unger rel eased, there shoul d be
conti nui ty between Pi n 5 and Pi n 6.
(3) Wi th swi tch pl unger depressed, there shoul d be
conti nui ty:
Between Pi n 1 and Pi n 2.
Between Pi n 3 and Pi n 4.
(4) I f the above resul ts are not obtai ned, the stop
l amp swi tch i s defecti ve or out of adjustment.
(5) Stop l amp swi tch adjustment i s detai l ed i n
Group 5, Brakes.
ELECTRICAL TESTS AT POWERTRAIN CONTROL
MODULE
(1) Unpl ug the GRAY 40-way connector from the
Powertrai n Control Modul e (PCM), (Fi g. 5).
(2) Remove both steeri ng wheel speed control
swi tches and di sconnect the wi re connectors.
Fig. 3 Servo Harness Connector
Fig. 4 Stop Lamp Wiring
Fig. 5 Powertrain Control Module Location
(a) Usi ng an ohmmeter, check for conti nui ty
between cavi ty 41 of the PCM connector and cavi ty
1 of each speed control swi tch connector (Fi g. 6).
(b) I f no conti nui ty, repai r as necessary.
(c) Usi ng an ohmmeter, check for conti nui ty
between cavi ty 41 of the PCM connector and
ground.
(d) I f conti nui ty, repai r as necessary.
(e) I f no conti nui ty, perform the Swi tch Test.
(f) Pl ug GRAY 40 way connector i nto PCM.
(g) Pl ug swi tch connectors back i nto swi tches.
(3) Unpl ug speed control servo el ectri cal connector.
(4) Pl ace i gni ti on swi tch i n the ON posi ti on and
turn on the speed control system, for the fol l owi ng
tests.
(a) Usi ng a vol tmeter, measure vol tage from cav-
i ty 3 of servo connector to ground. Vol tmeter
shoul d read i gni ti on vol tage. I f vol tage i s l ow, ski p
to Step 7.
(b) Turn speed control and i gni ti on swi tch OFF.
Usi ng an ohmmeter, pl ace posi ti ve l ead on pi n 3
and negati ve l ead on pi n 4 on the speed control
servo. Check conti nui ty from pi n 3 to pi n 4.
(c) I f no conti nui ty, repl ace the speed control
servo. I f conti nui ty i s greater than 49 ohms, cl ean
termi nal s.
(d) Usi ng an ohmmeter, pl ace posi ti ve l ead on
pi n 3 and negati ve l ead on pi n 2 on the speed con-
trol servo. Check conti nui ty from pi n 3 to pi n 2.
(e) I f no conti nui ty, repl ace the speed control
termi nal s.
(f) Usi ng an ohmmeter, pl ace posi ti ve l ead on
pi n 3 and negati ve l ead on pi n 1 on the speed con-
trol servo. Check conti nui ty from pi n 3 to pi n 1.
(g) I f no conti nui ty, repl ace the speed control
termi nal s.
(h) Usi ng an ohmmeter at the servo connector,
pl ace posi ti ve l ead on cavi ty 4 and negati ve l ead on
ground. Check conti nui ty from cavi ty 4 to ground.
I f no conti nui ty, repai r open ci rcui t.
(i ) Unpl ug 2 40-way PCM connectors.
(j) Usi ng an ohmmeter, check conti nui ty from
cavi ty 1 of servo connector to cavi ty 56 (2.4, 3.3,
3.8L) or cavi ty 78 (3.0L) on PCM connector. I f no
conti nui ty, repai r open ci rcui t.
(k) Usi ng an ohmmeter, check conti nui ty from
cavi ty 1 of servo connector to ground. I f conti nui ty,
repai r as necessary.
(l ) I f conti nui ty i s OK, check conti nui ty from
cavi ty 2 of servo connector to cavi ty 80 of PCM
connector. I f no conti nui ty, repai r open ci rcui t.
(m) Usi ng an ohmmeter, check conti nui ty from
cavi ty 2 of servo connector to ground. I f conti nui ty,
(n) Usi ng an ohmmeter, check conti nui ty from
cavi ty 1 of servo connector to cavi ty 2 of servo con-
nector. I f conti nui ty, repai r as necessary.
(o) Reconnect the 4 way connector to servo.
(5) Usi ng an ohmmeter, check conti nui ty from cav-
i ty 62 of the PCM connector to ground. I f conti nui ty
i s OK wi th brake pedal i n unpressed posi ti on, pro-
ceed to Step 6.
(a) I f no conti nui ty, perform the Stop Lamp
swi tch test. Repl ace or adjust swi tch as requi red.
(b) I f swi tch passes test, check conti nui ty from
cavi ty 62 of the PCM connector to cavi ty 1 of the
stop l amp swi tch connector. Repai r open ci rcui t as
requi red.
(c) I f conti nui ty i s OK between cavi ty 62 and
cavi ty 1, repai r open ci rcui t between cavi ty 2 of the
stop l amp swi tch connector and ground.
i ty 76 on PCM connector to ground wi th the trans-
mi ssi on i n dri ve. I f conti nui ty, test TRS/ Park-
Neutral swi tch and swi tch wi ri ng.
(7) Turn speed control and i gni ti on swi tch OFF.
(8) Unpl ug the BLACK 40-way connector from the
Powertrai n Control Modul e (PCM).
i ty 3 of servo connector to cavi ty 5 on the PCM con-
nector.
(a) I f no conti nui ty, ski p to Step 10.
(b) I f conti nui ty i s OK, check conti nui ty from
pi n 5 of PCM connector to ground. I f conti nui ty,
repai r short to ground. I f no contuni ty, repl ace
PCM. Jump to Step 11.
(10) Remove stop l amp swi tch and conduct Stop
Lamp Swi tch Test. I f test fai l s, adjust or repl ace as
necessary.
(a) I f swi tch passes, measure conti nui ty from
cavi ty 4 of stop l amp swi tch connector to cavi ty 3
of servo connector. Repai r open ci rcui t i f necessary.
(b) I f conti nui ty i s OK, measure conti nui ty from
cavi ty 3 of stop l amp swi tch to cavi ty 5 of PCM
connector. Repai r open ci rcui t as necessary.
(11) I nstal l PCM connectors onto PCM and speed
control servo connector to servo.
Fig. 6 PCM 40Way Connectors
VACUUM SUPPLY TEST
(1) Di sconnect vacuum hose at the servo and
i nstal l a vacuum gauge i n the hose (Fi g. 7).
(2) Start engi ne and observe gauge at i dl e. Vac-
uum gauge shoul d read at l east ten i nches of mer-
cury. Shut off engi ne, the vacuum shoul d conti nue to
hol d 10 i nches of mercury.
(3) I f vacuum does not meet thi s requi rement,
check and correct the fol l owi ng vacuum l eaks i n the
vacuum l i nes, check val ve, vacuum reservoi r or poor
engi ne performance.
VEHICLE SPEED SENSOR
For di agnosi s and testi ng of the Vehi cl e Speed Sen-
sor (VSS), refer to the appropri ate Powertrai n Di ag-
nosti c Procedures servi ce manual . Al so refer to the
DRB scan tool .
SPEED CONTROL SERVO
REMOVAL
(2) On vehi cl es wi th 3.3/3.8 L engi ne, remove ai r
cl eaner resonator. Refer to Group 14, Fuel System for
proper procedure.
(3) Di sconnect the throttl e and speed control cabl e
ends from throttl e body (Fi g. 8).
(4) Depress l ock tabs hol di ng speed control cabl e
casi ng to cabl e mount bracket (Fi g. 9).
(5) Di sconnect vacuum l i ne from ni ppl e on ai r
i ntake pl enum.
(6) Remove ti e wrap hol di ng vacuum l i ne, throttl e
cabl e, and speed control cabl e together.
(7) Remove bol t hol di ng speed control servo to si de
of battery tray/vacuum reservoi r (Fi g. 10).
(8) Remove speed control servo from battery tray.
(9) Di sconnect wi re connector from speed control
servo.
(10) Di sconnect vacuum l i ne from speed control
servo that l eads to the battery tray/vacuum reservoi r.
(11) Remove speed control servo.
Fig. 7 Vacuum Gauge Test
Fig. 8 Speed Control Cable End
Fig. 9 Speed Control Cable Case and Vacuum
LineTypical
INSTALLATION
Transfer speed control cabl e to repl acement speed
control servo. Reverse the precedi ng operati on.
SPEED CONTROL SWITCHES
REMOVAL
(3) Remove ai rbag/horn pad from steeri ng wheel ,
refer to Group 8M, Restrai nt Systems for proper pro-
cedures.
(4) Di sconnect wi re connector from horn swi tch,
ai rbag, and speed control swi tches.
(5) Remove screws hol di ng speed control swi tch to
ai rbag/horn pad (Fi g. 11).
(6) Separate speed control swi tch from ai rbag/horn
pad.
INSTALLATION
Reverse the precedi ng operati on.
STOP LAMP SWITCH
REMOVAL
Remove the swi tch from the bracket by depressi ng
the brake pedal and rotati ng the swi tch i n a counter-
cl ockwi se di recti on approxi matel y 30 degrees. Pul l
the swi tch rearward and remove from bracket. Di s-
connect wi ri ng harness connector.
INSTALLATION
Before i nstal l i ng the swi tch, reset the adjustabl e
swi tch pl unger by pul l i ng on the pl unger head unti l
the pl unger reaches the end of i ts travel . A ratchet-
i ng sound wi l l be heard duri ng thi s procedure.
Connect the wi ri ng harness to the swi tch. Mount
the swi tch i nto the bracket by hol di ng the swi tch
wi th the pl unger faci ng forward i n car. There i s an
i ndex key on the swi tch that mates wi th the bracket
sl ot at the top of the square hol e. Al i gn key and push
swi tch i nto square hol e i n bracket whi l e depressi ng
the brake pedal . Once the swi tch i s seated i n the
hol e, rotate cl ockwi se approxi matel y 30 degrees to
l ock i nto pl ace. The swi tch wi l l automati cal l y adjust
when the pedal i s rel eased. Pul l back on the pedal to
assure correct adjustment.
SPEED CONTROL CABLE
REMOVAL
(2) On vehi cl es wi th 3.3/3.8 L engi ne, remove ai r
cl eaner resonator. Refer to Group 14, Fuel System for
proper procedure.
(3) Di sconnect throttl e and speed control cabl e
ends from throttl e body (Fi g. 8).
(4) Depress l ock tabs hol di ng speed control cabl e
casi ng to cabl e mount bracket (Fi g. 12).
(5) Remove ti e wrap hol di ng vacuum l i ne, throttl e
cabl e, and speed control cabl e together.
(6) Remove nuts hol di ng speed control cabl e case
to servo.
(7) Remove cabl e case from servo.
(8) Remove hai rpi n cl i p hol di ng cabl e end to servo
di aphragm (Fi g. 12).
(9) Remove speed control cabl e.
INSTALLATION
Reverse the precedi ng operati on.
For Removal /I nstal l ati on refer to Powertrai n Con-
trol Modul e i n Group 14, Fuel I njecti on System.
THE ORGINAL VEHICLES MILAGE. IF THIS
Fig. 10 Speed Control Servo
Fig. 11 Speed Control Switches
STEP IS NOT DONE A DIAGONSTIC TROUBLE
VACUUM RESEROIR
REMOVAL
(2) Remove battery, Refer to Group 8B, for Battery
Removal /I nstal l ati on
(3) Remove battery tray.
(4) Di sconnect vacuum hoses from vacuum reser-
voi r
INSTALLATION
(1) Connect vacuum hoses to vacuum reservoi r.
(2) I nstal l battery tray
(3) I nstal l battery, Refer to Group 8B, for Battery
For Removal /I nstal l ati on, refer to Vehi cl e Speed
Sensor i n Group 14, Fuel I njecti ons.
Fig. 12 Speed Control Cable
VEHICLE SPEED CONTROL SYSTEM
CONTENTS
page
GENERAL INFORMATION
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . 1
GENERAL INFORMATION
INTRODUCTION
Thi s group covers both Left-Hand Dri ve (LHD) and
Ri ght-Hand Dri ve (RHD) versi ons of thi s model .
Whenever feasi bl e, the RHD versi ons of affected
vehi cl e components have been constructed as mi rror-
i mage of the LHD versi ons. Whi l e most of the i l l us-
trati ons used i n thi s group represent onl y the LHD
versi on, the di agnosti c and servi ce procedures out-
l i ned can general l y be appl i ed to ei ther versi on.
Excepti ons to thi s rul e have been cl earl y i denti fi ed as
LHD or RHD, i f a speci al i l l ustrati on or procedure
was/i s requi red.
The speed control system used wi th the 2.5L di esel
engi ne i s basi cal l y i denti cal to the system used wi th
gasol i ne powered engi nes. Features uni que to the
di esel engi ne wi l l be covered i n thi s secti on.
Model s equi pped wi th the 2.5L di esel engi ne do
not use a vacuum reservoi r to retai n engi ne vacuum
for speed control operati on. There are no vaccum-op-
erated speed control servos used i n vehi cl es wi th the
2.5L di esel engi ne.
The range of the speed control system operati on
i s restri cted to speeds between 56 km/h (35 MPH) to
145 km/h (90 MPH).
I nputs to the MSA that al l ow speed control oper-
ati on are from the vehi cl e speed sensor and the
Speed Control Swi tch.
Two separate speed control swi tch modul es are
mounted on the steeri ng wheel to the l eft and ri ght
si de of the dri vers ai rbag modul e. Swi tch features
are:
a. Wi thi n the two swi tch modul es, fi ve momen-
tary contact swi tches, supporti ng seven di fferent
speed control functi ons are used.
b. The outputs from these swi tches are fi l tered
i nto one i nput. The MSA determi nes whi ch output
has been appl i ed through resistive multiplexing.
The i nput ci rcui t vol tage i s measured by the MSA
to determi ne whi ch swi tch functi on has been
sel ected.
c. A speed control i ndi cator l amp, l ocated on the
i nstrument panel cl uster i s energi zed by the MSA
vi a the CCD Bus. Thi s occurs when speed control
system power has been turned ON, and the engi ne
i s runni ng.
d. The two swi tch modul es are l abel ed: ON/OFF,
SET, RESUME/ACCEL, CANCEL and COAST.
Refer to the owners manual for more i nformati on
on speed control swi tch functi ons and setti ng pro-
cedures. The i ndi vi dual swi tches cannot be
repai red. I f one i ndi vi dual swi tch fai l s, the swi tch
modul e must be repl aced.
NS/GS VEHICLE SPEED CONTROL SYSTEM 8H - 1
TURN SIGNAL AND FLASHERS
CONTENTS
page page
GENERAL INFORMATION
COMBINATION FLASHER . . . . . . . . . . . . . . . . . . 1
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . 1
COMBINATION FLASHER / DAYTIME
RUNNING LAMPS (DRL) MODULE . . . . . . . . . 2
COMBINATION FLASHER FUNCTION . . . . . . . . . 1
COMBINATION FLASHER WITH / WITHOUT
DAYTIME RUNNING LAMPS MODULE
CIRCUIT DIAGNOSTICS . . . . . . . . . . . . . . . . . . 3
TURN SIGNAL MULTI-FUNCTION SWITCH . . . . 2
DRL MODULE . . . . . . . . . . . . . . . . . . . . . . . . 11
MULTI-FUNCTION SWITCH . . . . . . . . . . . . . . . 11
GENERAL INFORMATION
INTRODUCTION
The turn si gnal s are actuated wi th a l ever on the
l eft si de of the steeri ng col umn just ahead of the
steeri ng wheel . The si gnal s are automati cal l y turned
off by a cancel i ng cam (two l obes mol ded to the cl ock-
spri ng mechani sm). The cam comes i n contact wi th
the cancel actuator on the turn si gnal (mul ti -func-
ti on) swi tch assembl y. Ei ther cam l obe, pushi ng on
the cancel actuator, returns the swi tch to the OFF
posi ti on.
Lane change si gnal i ng i s actuated by appl yi ng par-
ti al turn si gnal stal k movement toward the di recti on
desi red unti l the i ndi cator l amps fl ashes i n the
i nstrument cl uster. When the swi tch stal k i s rel eased
the stal k wi l l spri ng back i nto the neutral posi ti on
turni ng OFF the turn si gnal .
Wi th the i gni ti on swi tch ON and the turn si gnal
swi tch stal k actuated l eft or ri ght, current fl ows
through the:
Combi nati on fl asher
Mul ti -functi on swi tch
Turn i ndi cator l amp
Front and rear turn si gnal bul bs.
A chi me wi l l sound after the vehi cl e has travel ed a
di stance of approxi matel y 0.5 mi l e wi th the turn si g-
nal ON.
COMBINATION FLASHER
The Turn Si gnal /Hazard Warni ng Fl asher i s a
modul e provi di ng the vehi cl e wi th turn si gnal and
hazard warni ng functi ons and has been desi gned
wi th i nternal rel ays to take advantage of l ow current
swi tchi ng requi rements i n the vehi cl e. I t i s pl ugged
i nto the Juncti on Bl ock at posi ti on 4 (Fi g. 1), where
al l wi ri ng associ ated wi th i ts operati on i s termi nated.
The Juncti on Bl ock i s adjacent to and l eft of the
steeri ng col umn of the vehi cl e.
To gai n access to the fl asher, remove the l ower
steeri ng col umn cover and knee bl ocker. Refer to
Group 8E, I nstrument Panel and Systems for
removal procedures.
COMBINATION FLASHER FUNCTION
The Turn Si gnal /Hazard Warni ng Fl asher i s a
modul e provi di ng turn si gnal , hazard warni ng func-
ti ons and has been desi gned wi th i nternal rel ays to
Fig. 1 Combination Flasher Location
NS TURN SIGNAL AND FLASHERS 8J - 1
take advantage of l ow current swi tchi ng requi re-
ments i n the vehi cl e. I t i s pl ugged i nto the Juncti on
Bl ock at posi ti ons 4 (Fi g. 1) where al l wi ri ng associ -
ated wi th i ts operati on i s termi nated. The Juncti on
Bl ock i s adjacent to and l eft of the steeri ng col umn of
the vehi cl e.
To gai n access to the devi ce, remove the l ower
steeri ng col umn cover and knee bl ocker, refer to
Group 8E, I nstrument Panel and Systems.
The combi nati on fl asher may be operated i n i ts
hazard warni ng mode ei ther wi th or wi thout the i gni -
ti on ci rcui t bei ng acti ve. However, i n order to operate
i n the turn si gnal mode, the i gni ti on ci rcui t must be
compl eted to the modul e.
Whi l e the combi nati on fl asher i s i dl e, there i s no
current drawn through the modul e. The devi ce does
not become acti ve unti l a si gnal ground ci rcui t i s
suppl i ed to ei ther of the turn si gnal i nputs or the
hazard warni ng i nput.
Typi cal fl ash rate for the fl asher i s 90 fl ashes per
mi nute.
When a l amp i s burnt out for a gi ven si de of the
vehi cl e or a wi re i s open to a l amp, the fl ash rate wi l l
i ncrease to 180 fl ashes per mi nute when i n the turn
si gnal mode. When i n the hazard warni ng si gnal
mode the fl ash rate remai ns at 90 fl ashes per
mi nute.
Turn si gnal i nputs that actuate the fl asher are l ow
current grounds, each drawi ng a maxi mum of 300
mA., and are provi ded to the fl asher through the
Juncti on Bl ock from the mul ti -functi on swi tch that i s
mounted to the steeri ng col umn. The hazard warni ng
si gnal i nput i s a l ow current ground drawi ng a max-
i mum of 600 mA. through the mul ti -functi on swi tch.
COMBINATION FLASHER / DAYTIME RUNNING
LAMPS (DRL) MODULE
The Combi nati on Fl asher/DRL i s a modul e provi d-
i ng turn si gnal , hazard warni ng, and dayti me run-
ni ng l i ght functi ons, and has been desi gned wi th
i nternal rel ays to take advantage of l ow current
swi tchi ng requi rements i n the vehi cl e. I t i s pl ugged
i nto the juncti on bl ock at posi ti ons 3 AND 4 (Fi g. 2)
where al l wi ri ng associ ated wi th i ts operati on i s ter-
mi nated. The Juncti on Bl ock i s adjacent to and l eft of
the steeri ng col umn of the vehi cl e.
steeri ng col umn cover and knee bl ocker, refer to
Group 8E, I nstrument Panel and Gauges.
The combi nati on fl asher/DRL may be operated i n
i ts hazard warni ng mode ei ther wi th or wi thout the
i gni ti on ci rcui t bei ng acti ve. However, i n order to
operate i n the turn si gnal mode or the DRL mode,
the i gni ti on ci rcui t must be compl eted to the modul e.
Whi l e the combi nati on fl asher porti on i s i dl e, there
i s no current drawn through the modul e. The devi ce
does not become acti ve i n the turn si gnal or hazard
warni ng modes unti l a si gnal ground ci rcui t i s sup-
pl i ed to ei ther of the turn si gnal i nputs or the hazard
warni ng i nput. Wi th the i gni ti on OFF, there i s no
current drawn through the modul e.
Whi l e the i gni ti on i s ON, the front turn si gnal fi l -
aments are i l l umi nated steadi l y thus provi di ng the
DRL functi on. The DRL functi on may be i nhi bi ted by
appl yi ng a si gnal ground i nput from ei ther the park
brake ci rcui t or the headl amp rel ay acti vati on ci rcui t.
Typi cal fl ash rate for the fl asher i s 90 fl ashes per
mi nute.
When a l amp i s burnt out for a gi ven si de of the
vehi cl e or a wi re i s open to a l amp, the fl ash rate wi l l
i ncrease to 180 fl ashes per mi nute when i n the turn
si gnal mode. When i n the hazard warni ng si gnal
mode the fl ash rate remai ns at 90 fl ashes per
mi nute.
Turn si gnal i nputs that actuate the fl asher are l ow
current grounds, each coul d draw a maxi mum of 300
mA., and are provi ded to the fl asher through the
Juncti on Bl ock from the mul ti -functi on swi tch that i s
mounted to the steeri ng col umn. The hazard warni ng
si gnal i nput i s a l ow current ground that coul d draw
a maxi mum of 600 mA. through the mul ti -functi on
swi tch.
TURN SIGNAL MULTI-FUNCTION SWITCH
To test turn si gnal , headl amp beam sel ect and opti -
cal horn porti on of the mul ti -functi on swi tch:
(1) Remove the mul ti -functi on swi tch, refer to
removal procedures.
(2) Usi ng an ohmmeter check conti nui ty readi ng
between mul ti -functi on swi tch pi ns. Refer to (Fi g. 3)
for proper pi n numbers and Turn Si gnal Mul ti -Func-
ti on Swi tch Test chart.
Fig. 2 Junction Block Terminal Pins
8J - 2 TURN SIGNAL AND FLASHERS NS
DAYTIME RUNNING LAMPS MODULE CIRCUIT
DIAGNOSTICS
The battery i nput (Pi n 1), i s brought i nto the Juncti on
Bl ock through the El ectri cal Di stri buti on Wi ri ng (EDW)
harness (Fi g. 4). I t ori gi nates under the hood i n the
Power Di stri buti on Center (PDC) through a 20 ampere
fuse at posi ti on 10 (9th posi ti on from the upper end) and
l abel ed HAZARD. Thi s ci rcui t (L09) i s the onl y power
feed to the combi nati on-fl asher/DRL.
The i gni ti on i nput of Pi n 6 (refer to Juncti on Bl ock
Termi nal Cal l -Out and Juncti on Bl ock Termi nal Cal l -Out
wi th DRL tabl es) onl y senses that the i gni ti on ci rcui t i s
ON and does not suppl y current to the modul e i n a way
that woul d power the system. Thi s RUN/START ci rcui t i s
brought i nto the juncti on bl ock to a 10 ampere fuse
l abel ed TS BU LMP at the bottom ri ght si de. The ci rcui t
desi gnati on out of the fuse i s A22D. Thi s ci rcui t feeds the
combo-fl asher and the fol l owi ng systems wi th I gni ti on
vol tage i f the vehi cl e i s so equi pped:
Back-Up Lamps
El ectrochromi c I nsi de Rear vi ew Mi rror
A/C Control Head
Mi ni -Tri p Computer
ABS Modul e
Front Bl ower Rel ay Coi l
Rear Bl ower Rel ay Coi l
AWD Sol enoi ds
Rear Wi ndow Defogger (EBL) Rel ay Coi l
The i gni ti on i nput to the combo-fl asher wi l l draw
typi cal l y 5 mA of current whi l e acti ve.
For di agnosti c test procedures, refer to Combi na-
ti on Fl asher Di agnosi s tabl es.
Fig. 4 Electronic Combination Flasher Circuit
Fig. 3 Turn SignalMulti-Function Switch Pin
numbers
TURN SIGNAL MULTI-FUNCTION SWITCH
TEST
SWITCH POSITION
CONTINUITY
BETWEEN
LEFT 4 AND 8
RIGHT 3 AND 8
HAZARD 1 AND 8
LO BEAM 9 AND 10
HI BEAM 9 AND 121
Fig. 5 Electronic Combination Flasher with DRL Circuit
J UNCTION BLOCK TERMINAL CALL-OUT
CAV. CKT. WIRE
GAUGE
COLOR FUNCTION
1 L09 18 BLK/WT BATTERY INTPUT MAIN FEED
2 L61 18 LG LEFT FRONT T/S OUTPUT TO LAMP
3 L60 18 TN RIGHT FRONT T/S OUTPUT TO LAMP
4 L63 18 DG/RD LEFT REAR T/S OUTPUT TO LAMP
5 L62 18 BR/RD RIGHT REAR T/S OUTPUT TO LAMP
6 A22D 20 BK/OR IGNITION INPUT SENSE ONLY
7 L305 22 LB/WT LEFT T/S SWITCH INPUT SENSE ONLY
8 L302 22 LB/YL RIGHT T/S SWITCH INPUT SENSE ONLY
9 L91 22 DB/PK HAZARD SWITCH INPUT SENSE ONLY
J UNCTION BLOCK TERMINAL CALL-OUT WITH DRL
CAV. CKT. WIRE
GAUGE
COLOR FUNCTION
1 L09 18 BLK/WT BATTERY INTPUT MAIN FEED
2 L61 18 LG LEFT FRONT T/S OUTPUT TO LAMP
3 L60 18 TN RIGHT FRONT T/S OUTPUT TO LAMP
4 L63 18 DG/RD LEFT REAR T/S OUTPUT TO LAMP
5 L62 18 BR/RD RIGHT REAR T/S OUTPUT TO LAMP
6 A22D 20 BK/OR IGNITION INPUT SENSE ONLY
7 L305 22 LB/WT LEFT T/S SWITCH INPUT SENSE ONLY
8 L302 22 LB/YL RIGHT T/S SWITCH INPUT SENSE ONLY
9 L91 22 DB/PK HAZARD SWITCH INPUT SENSE ONLY
10 G09 22 GY/BK PARK BRAKE SWITCH INPUT SENSE ONLY
11 Z01 14 BK GROUND MAIN GRD.
12 L93 22 RD/YL HEADLAMP RELAY SWITCH
INPUT
SENSE ONLY
COMBINATION FLASHER DIAGNOSIS
SYSTEM WILL NOT FLASH
HAZARD WARNING LAMPS
1. FAULTY (20) AMP FUSE N
POWER DISTRIBUTION CENTER
(PDC).
2. FAULTY WIRING CONNECTION
BETWEEN BOTTOM SIDE OF PDC
AND JUNCTION BLOCK.
3. FAULTY GROUND FEED TO
MULTI-FUNCTION SWITCH.
4. FAULTY HAZARD WARNING
SWITCH CONTACT.
5. COMBINATION FLASHER NOT
PLUGGED INTO JUNCTION
BLOCK.
6. FAULTY COMBINATION
FLASHER.
7. FAULTY TERMINALS IN
JUNCTION BLOCK.
1. REPLACE FAULTY FUSE IN
PDC.
2. REPAIR FAULTY WIRING
CONNECTION FROM PDC TO
JUNCTION BLOCK.
3. REPAIR OR REPLACE FAULTY
GROUND WIRE FEED TO
4. REPLACE FAULTY MULTI-
FUNCTION SWITCH.
5. PLUG COMBINATION FLASHER
INTO JUNCTION BLOCK.
6. REPLACE FAULTY
COMBINATION FLASHER.
7. REPLACE JUNCTION BLOCK.
SYSTEM WILL FLASH HAZARD
WARNING LAMPS BUT WILL
NOT FLASH RIGHT OR LEFT
TURN SIGNAL LAMPS
1. FAULTY (10) AMP FUSE IN THE
JUNCTION BLOCK.
FLASHER.
3. FAULTY MULTI-FUNCTION
SWITCH CONTACTS.
JUNCTION BLOCK.
JUNCTION BLOCK.
2. REPLACE COMBINATION
FLASHER.
FUNCTION SWITCH.
WARNING LAMPS AND RIGHT
TURN SIGNAL LAMPS, BUT WILL
NOT FLASH LEFT TURN SIGNAL
LAMPS
1. FAULTY LEFT TURN SIGNAL
WIRING CONNECTION BETWEEN
JUNCTION BLOCK AND MULTI-
FUNCTION SWITCH.
FLASHER.
SWITCH CONTACTS.
JUNCTION BLOCK.
FUNCTION SWITCH.
FLASHER.
FUNCTION SWITCH.
RIGHT TURN SIGNAL
OPERATES PROPERLY BUT
LEFT TURN SIGNAL FLASHES
FAST
1. FAULTY LEFT FRONT OR LEFT
REAR TURN SIGNAL LAMP.
FROM JUNCTION BLOCK TO LEFT
FRONT OR LEFT REAR TURN
SIGNAL LAMP.
3. FAULTY GROUND WIRING
CONNECTION FROM LEFT
SIGNAL LAMP.
SWITCH CONTACTS.
JUNCTION BLOCK.
1. REPLACE LEFT FRONT OR
LEFT REAR TURN SIGNAL LAMP.
2. REPAIR OR REPLACE WIRING
CONNECTION FROM JUNCTION
BLOCK TO LEFT FRONT OR LEFT
GROUND WIRING CONNECTION
TO LEFT FRONT OR LEFT REAR
TURN SIGNAL LAMP.
FUNCTION SWITCH.
LEFT TURN SIGNAL OPERATES
PROPERLY BUT RIGHT TURN
SIGNAL FLASHES FAST
1. FAULTY RIGHT FRONT OR
RIGHT REAR TURN SIGNAL LAMP.
FROM JUNCTION BLOCK TO
RIGHT FRONT OR RIGHT REAR
TURN SIGNAL LAMP.
CONNECTION FROM RIGHT
FRONT OR RIGHT REAR TURN
SIGNAL LAMP.
SWITCH CONTACTS.
JUNCTION BLOCK.
1. REPLACE RIGHT FRONT OR
BLOCK TO RIGHT FRONT OR
TO RIGHT FRONT OR RIGHT
FUNCTION SWITCH.
BOTH TURN SIGNAL
INDICATORS IN MESSAGE
CENTER DO NOT FLASH IN
CONJUNCTION WITH OUTSIDE
TURN SIGNAL LAMPS
CONNECTION FROM COWL
GROUND SPLICE.
GROUND SPLICE.
LEFT OR RIGHT TURN SIGNAL
INDICATOR IN MESSAGE
CENTER DOES NOT FLASH IN
TURN SIGNAL LAMPS, BUT
OTHER INDICATOR PERFORMS
PROPERLY
1. FAULTY INDICATOR LAMP IN
MESSAGE CENTER.
BETWEEN MESSAGE CENTER
AND JUNCTION BLOCK.
1. REPLACE FAULTY INDICATOR
LAMP IN MESSAGE CENTER.
MESSAGE CENTER AND
JUNCTION BLOCK.
COMBINATION FLASHER DIAGNOSIS WITH DRL
SYSTEM WILL NOT FLASH
HAZARD WARNING LAMPS
1. FAULTY (20) AMP FUSE N
POWER DISTRIBUTION CENTER
(PDC).
BETWEEN BOTTOM SIDE OF PDC
AND JUNCTION BLOCK.
4. FAULTY HAZARD WARNING
SWITCH CONTACT.
5. COMBINATION FLASHER/DRL
MODULE NOT PLUGGED INTO
JUNCTION BLOCK.
FLASHER/DRL MODULE.
JUNCTION BLOCK.
PDC.
2. REPAIR FAULTY WIRING
CONNECTION FROM PDC TO
JUNCTION BLOCK.
GROUND WIRE FEED TO
FUNCTION SWITCH.
5. PLUG COMBINATION FLASHER/
DRL MODULE INTO JUNCTION
BLOCK.
6. REPLACE FAULTY
COMBINATION FLASHER/DRL
MODULE.
WARNING LAMPS BUT WILL
NOT FLASH RIGHT OR LEFT
TURN SIGNAL LAMPS
1. FAULTY (10) AMP FUSE IN THE
JUNCTION BLOCK.
FLASHER/DRL MODULE.
SWITCH CONTACTS.
JUNCTION BLOCK.
JUNCTION BLOCK.
FLASHER/DRL MODULE.
FUNCTION SWITCH.
RIGHT TURN SIGNAL
OPERATES PROPERLY BUT
LEFT TURN SIGNAL FLASHES
FAST
(Hazard mode can be used for a
system check)
1. FAULTY LEFT FRONT OR LEFT
FROM JUNCTION BLOCK TO LEFT
SIGNAL LAMP.
CONNECTION FROM LEFT
SIGNAL LAMP.
SWITCH CONTACTS.
JUNCTION BLOCK.
1. REPLACE LEFT FRONT OR
LEFT REAR TURN SIGNAL LAMP.
BLOCK TO LEFT FRONT OR LEFT
TO LEFT FRONT OR LEFT REAR
TURN SIGNAL LAMP.
FUNCTION SWITCH.
LEFT TURN SIGNAL OPERATES
PROPERLY BUT RIGHT TURN
SIGNAL FLASHES FAST
(Hazard mode can be used for a
system check)
1. FAULTY RIGHT FRONT OR
FROM JUNCTION BLOCK TO
RIGHT FRONT OR RIGHT REAR
TURN SIGNAL LAMP.
CONNECTION FROM RIGHT
FRONT OR RIGHT REAR TURN
SIGNAL LAMP.
SWITCH CONTACTS.
JUNCTION BLOCK.
1. REPLACE RIGHT FRONT OR
BLOCK TO RIGHT FRONT OR
TO RIGHT FRONT OR RIGHT
FUNCTION SWITCH.
BOTH TURN SIGNAL
INDICATORS IN MESSAGE
CENTER DO NOT FLASH IN
TURN SIGNAL LAMPS
GROUND SPLICE.
GROUND SPLICE.
LEFT OR RIGHT TURN SIGNAL
INDICATOR IN MESSAGE
CENTER DOES NOT FLASH IN
TURN SIGNAL LAMPS, BUT
OTHER INDICATOR PERFORMS
PROPERLY
1. FAULTY INDICATOR LAMP IN
MESSAGE CENTER.
BETWEEN MESSAGE CENTER
AND JUNCTION BLOCK.
1. REPLACE FAULTY INDICATOR
LAMP IN MESSAGE CENTER.
MESSAGE CENTER AND
JUNCTION BLOCK.
TURN SIGNAL AND HAZARD
WARNING FLASHERS
FUNCTION PROPERLY BUT
DAYTIME RUNNING LIGHTS
(DRL) DO NOT COME ON WHILE
DRIVING
(The brake lamp in the message
center remains illuminated under
the circumstances noted to the
right in step #3.0 through 3.5
unless the lamp is burned out.)
(Headlamps, either low or high
beam, remain illuminated under
the circumstances noted to the
right in step #4.0 through 4.3 even
though the headlamp switch is
OFF.)
JUNCTION BLOCK FROM
GROUND STUD CONNECTOR
THROUGH I/P HARNESS.
2. FAULTY GROUND FEED
THROUGH JUNCTION BLOCK TO
CAVITY #11 IN POSITION #3 OF
THE JUNCTION BLOCK.
3.0. FAULTY PARK BRAKE
SWITCH.
3.1. PARK BRAKE INPUT CIRCUIT
FALSELY GROUNDED. COULD BE
THE G09 CIRCUIT WHICH IS A
(20) GA. GY/BK WIRE BETWEEN
THE MESSAGE CENTER AND THE
JUNCTION BLOCK,
3.2. OR BETWEEN THE PARK
BRAKE SWITCH AND THE
JUNCTION BLOCK,
3.3. OR BETWEEN THE BRAKE
PRESSURE SWITCH AND THE
JUNCTION BLOCK,
3.4. OR BETWEEN THE IGNITION
SWITCH AND THE JUNCTION
BLOCK,
3.5. OR A SHORTED IGNITION
SWITCH (CONTACT SHOULD
ONLY BE MADE WHEN IN START
POSITION).
4.0. L93 CIRCUIT FALSELY
GROUNDED BETWEEN JUNCTION
BLOCK AND MULTI-FUNCTION
SWITCH.
4.1. L307 CIRCUIT FALSELY
GROUNDED BETWEEN
HEADLAMP SWITCH AND BODY
CONTROL MODULE.
4.2. HEADLAMP SWITCH
SHORTED.
4.3. HEADLAMP CONTROL
OUTPUT FALSELY GROUNDED BY
BODY CONTROL MODULE.
1. REPLACE GROUND CIRCUIT TO
JUNCTION BLOCK.
3.0. REPLACE THE PARK BRAKE
SWITCH.
3.1-3.4. REPAIR THE G09 CIRCUIT
TO ELIMINATE THE FALSE
GROUND SOURCE.
3.5. REPLACE IGNITION SWITCH.
4.0. REPAIR OR REPLACE FAULTY
FUNCTION SWITCH.
4.1. REPAIR OR REPLACE FAULTY
HEADLAMP SWITCH AND BODY
CONTROL MODULE.
4.2. REPLACE SHORTED
HEADLAMP SWITCH.
4.3. REPLACE BODY CONTROL
MODULE.
MULTI-FUNCTION SWITCH
WARNING: BEFORE SERVICING A STEERING COL-
UMN EQUIPPED WITH AN AIRBAG REFER TO
GROUP 8M, RESTRAINT SYSTEMS FOR PROPER
AND SAFE SERVICE PROCEDURES.
REMOVAL
(2) Di sconnect and i sol ate battery negati ve cabl e.
(3) Remove upper and l ower steeri ng col umn
shrouds, refer to Group 19, Steeri ng for proper pro-
cedures.
(4) Di sconnect wi re connector from back of turn
si gnal mul ti -functi on swi tch (Fi g. 6).
(5) Remove screws hol di ng turn si gnal swi tch to
steeri ng col umn adapter col l ar.
(6) Remove turn si gnal swi tch.
INSTALLATION
For i nstal l ati on, reverse the above procedures. Ver-
i fy swi tch operati on by pl aci ng the control stal k i n
ei ther the ri ght or l eft posi ti on and turni ng the steer-
i ng wheel to ensure the automati c cancel l ati on of the
swi tch.
COMBINATION FLASHER WITH / WITHOUT DRL
MODULE
REMOVAL
(1) Remove l ower steeri ng col umn cover.
(2) Remove knee bl ocker.
(3) Pul l combi nati on fl asher from juncti on bl ock.
INSTALLATION
Fig. 6 Turn Signal Multi-Function Switch
WINDSHIELD WIPERS AND WASHERS
CONTENTS
page page
REAR WIPER AND WASHER . . . . . . . . . . . . . . . . 9 WINDSHIELD WIPERS AND WASHER . . . . . . . . . 1
WINDSHIELD WIPERS AND WASHER
INDEX
page page
GENERAL INFORMATION
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . 1
FAILED PARK SWITCH . . . . . . . . . . . . . . . . . . . . 2
MULTI-FUNCTION SWITCH . . . . . . . . . . . . . . . . . 4
MULTI-FUNCTION SWITCH . . . . . . . . . . . . . . . . . 4
WINDSHIELD WASHER BOTTLE . . . . . . . . . . . . . 4
WINDSHIELD WIPER BLADE ELEMENT . . . . . . . 6
WINDSHIELD WIPER BLADE . . . . . . . . . . . . . . . . 5
WINDSHIELD WIPER MOTOR . . . . . . . . . . . . . . . 6
WIPER ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
WIPER LINKAGE . . . . . . . . . . . . . . . . . . . . . . . . . 7
WIPER UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
WIPER BLADES . . . . . . . . . . . . . . . . . . . . . . . . . . 8
ADJUSTMENTS
WIPER ARM ALIGNMENT . . . . . . . . . . . . . . . . . . 8
GENERAL INFORMATION
INTRODUCTION
BAG, SEE GROUP 8M, RESTRAINT SYSTEMS FOR
SAFETY PRECAUTIONS. DISCONNECT THE NEGA-
TIVE CABLE FROM THE BATTERY BEFORE SER-
VICING COMPONENTS INVOLVING THE AIRBAG
SYSTEM. ACCIDENTAL DEPLOYMENT OF AIRBAG
AND PERSONAL INJURY CAN RESULT.
The wi ndshi el d wi pers can be operated wi th the
wi ndshi el d wi per swi tch when the i gni ti on swi tch i s
i n the RUN or ACCESSORY posi ti ons. The wi nd-
shi el d wi per system i s protected by a 40 amp fuse (9)
l ocated i n the Power Di stri buti on Center (PDC) i n
the engi ne compartment. The wi ndshi el d washer ci r-
cui t i s protected by a 6 amp fuse (9) l ocated i n the
Juncti on Bl ock. The wi per motor has permanent
magneti c fi el ds. The speeds are determi ned by cur-
rent fl ow to the appropri ate set of brushes i nsi de the
motor. The current fl ow i s control l ed by the mul ti -
functi on swi tch stal k mounted wi per swi tch, hi gh
speed/l ow speed rel ays l ocated i n the PDC. The speed
sensi ti ve i ntermi ttent wi per i s control l ed by the Body
Control Modul e (BCM). The i ntermi ttent mode, wi th
the vehi cl e travel i ng greater than 10.4 mph, has a
range of 0.5 to 18 seconds. Wi th the vehi cl e travel i ng
l ess than 10.4 mph, and the ti me del ay i s not
adjusted, ti me del ay doubl es to a range of 1 to 36
seconds. The wi per arms wi l l park at the base of the
wi ndshi el d just above the cowl cover after the wi per
swi tch i s turned OFF.
The wi ndshi el d wi per motor and l i nkage i s l ocated
i n an i ntegral wi per uni t at the rear of the engi ne
compartment. The wi per uni t must be removed to
gai n access to the wi per motor.
The wi ndshi el d wi per system operates i n several
modes:
Low and hi gh speed normal wi pe
Speed sensi ti ve i ntermi ttent wi pe
Wi pe after wash
Pul se wi pe
Park (swi tch OFF)
The wi ndshi el d wi per ci rcui ts are conti nuousl y
moni tored and control l ed by the Body Control Mod-
NS WINDSHIELD WIPERS AND WASHERS 8K - 1
ul e (BCM). I f a probl em occurs i n the el ectroni c com-
ponents, wi ri ng, swi tch (except i ntegral motor park
swi tch) and wi per motor a Di agnosti c Troubl e Code
(DTC) wi l l be stored i n the BCM memory. DTCs can
be retri eved usi ng a scan tool (DRB). Refer to proper
Body Di agnosti c Procedures manual for DTC descri p-
ti ons and retri eval i nformati on.
The wi ndshi el d wi per park swi tch and ci rcui t i s
moni tored by the BCM. The park swi tch and ci rcui t
can be tested usi ng the Wi per System Di agnosi s
chart.
FAILED PARK SWITCH
I f the wi per park swi tch has fai l ed the wi ndshi el d
wi pers wi l l operate as fol l ows:
SWITCH OFFWi pers stop i n current l ocati on
regardl ess of the park si gnal .
INTERMITTENT MODEWi pers operate at l ow
speed for one or more extra wi pes or conti nuousl y.
LOWSPEEDWi pers operate at l ow speed.
HIGH SPEEDWi pers operate at hi gh speed.
PULSE WIPEWi pers wi l l not operate.
WIPE AFTER WASHWi pers operate at l ow
speed i n any mode setti ng. Wi pers operate onl y whi l e
wash button i s depressed wi th swi tch i n OFF mode,
wi pers stop i n mi d-cycl e when button i s rel eased.
The wi ndshi el d wi per park swi tch and ci rcui t i s
moni tored by the BCM. The park swi tch and ci rcui t
can be tested usi ng the Wi per System Di agnosi s
tabl e.
WIPER SYSTEM DIAGNOSIS
WIPER BLADES DO NOT PARK
PROPERLY
1. WIPER ARMS IMPROPERLY
PARKED.
2. WIPER ARMS ARE LOOSE ON
PIVOT SHAFT.
3. MOTOR CRANK LOOSE AT
OUTPUT SHAFT.
1. REMOVE WIPER ARMS AND
REPARK. REFER TO WIPER ARM
REMOVAL AND INSTALLATION.
2. REMOVE WIPER ARM AND
REPARK. REFER TO WIPER ARM
3. REMOVE WIPER ARM, RUN
WIPER MOTOR TO PARK
POSITION AND REMOVE THE
MODULE. WITHOUT ROTATING
THE MOTOR OUTPUT SHAFT,
REMOVE THE CRANK AND CLEAN
ANY FOREIGN MATTER FROM
THE MOTOR SHAFT. INSTALL THE
MOTOR CRANK IN ITS ORIGINAL
POSITION.
MOTOR STOPS IN ANY
POSITION WHEN THE SWITCH
IS TURNED OFF
1. OPEN PARK CIRCUIT. 1. CHECK PARK SWITCH BY
DISCONNECTING THE WIRE
CONNECTOR AND APPLY
BATTERY VOLTAGE TO PIN 4.
PLACE A JUMPER WIRE FROM
PIN 2 TO PIN 3 AND THEN TO AN
EXTERNAL GROUND. REPLACE
MOTOR IF IT DOES NOT PARK.
MOTOR WILL NOT STOP WHEN
THE SWITCH IS TURNED OFF
1. FAULTY SWITCH.
2. LOCK OF DYNAMIC BRAKE ON
WET GLASS.
1. CHECK SWITCH IN LOW, HIGH
AND INTERMITTENT POSITION.
2. ENSURE PARK SWITCH HAS
CLEAN GROUND.
WIPER BLADES SLAP AGAINST
COWL SCREEN OR WINDOW
MOLDINGS.
1. WIPER ARMS ARE PARKED
INCORRECTLY.
1. PARK WIPER ARMS. REFER TO
WIPER ARM ADJUSTMENT.
8K - 2 WINDSHIELD WIPERS AND WASHERS NS
BLADES CHATTER 1. FOREIGN SUBSTANCE SUCH
AS POLISH ON GLASS OR
BLADES.
2. ARMS TWISTED, BLADE AT
WRONG ANGLE ON GLASS.
3. BLADE STRUCTURE BENT.
4. BLADE ELEMENT HAS
PERMANENT SET.
1. CLEAN GLASS AND BLADE
ELEMENT WITH NON-ABRASIVE
CLEANER.
2. REPLACE ARM.
3. REPLACE BLADE.
4. REPLACE BLADE ELEMENT.
WIPER KNOCK AT REVERSAL 1. LINKAGE BUSHINGS WORN.
2. ARMATURE ENDPLAY IN
MOTOR.
1. REPLACE WORN LINK. REFER
TO WIPER LINKAGE REMOVAL
AND INSTALLATION.
2. REPLACE WIPER MOTOR.
REFER TO WIPER MOTOR
WIPER MOTOR WILL NOT RUN 1. BLOWN FUSE.
2. NEW FUSE BLOWS.
3. NEW FUSE BLOWS.
4. NO VOLTAGE AT MOTOR.
5. POOR GROUND.
1. REPLACE FUSE, AND RUN
SYSTEM.
2. CHECK FOR SHORT IN WIRING
OR SWITCH.
3. REPLACE FUSE, REMOVE
MOTOR CONNECTOR, TURN
SWITCH ON, FUSE DOES NOT
BLOW, REPLACE MOTOR.
4. CHECK SWITCH AND WIRING
HARNESS. REFER TO GROUP 8W,
WIRING DIAGRAMS.
5. REPAIR GROUND WIRE
CONNECTION AS NECESSARY.
To test the wi ndshi el d wi per and washer porti on of
the mul ti -functi on swi tch:
(1) Remove the mul ti -functi on swi tch, refer to
removal procedures.
between swi tch pi ns, refer to (Fi g. 1) for proper pi n
numbers.
WARNING: BEFORE SERVICING A STEERING COL-
UMN EQUIPPED WITH AN AIRBAG REFER TO
GROUP 8M, RESTRAINT SYSTEMS FOR PROPER
AND SAFE SERVICE PROCEDURES.
REMOVAL
shrouds, refer to Group 19, Steeri ng for proper pro-
cedures.
(4) Di sconnect wi re connector from back of turn
si gnal mul ti -functi on swi tch (Fi g. 2).
(5) Remove screws hol di ng turn si gnal swi tch to
steeri ng col umn adapter col l ar.
(6) Remove turn si gnal swi tch.
INSTALLATION
For i nstal l ati on, reverse the above procedures. Ver-
i fy swi tch operati on by pl aci ng the control stal k i n
ei ther the ri ght or l eft posi ti on and turni ng the steer-
i ng wheel to ensure the automati c cancel l ati on of the
swi tch.
WINDSHIELD WASHER BOTTLE
REMOVAL
(2) Remove ri ght front wheel , refer to Group 22,
Wheel s and Ti res for proper procedures and ti ghten-
i ng sequences.
(3) Remove front wheel house spl ash shi el d.
(4) Di sconnect wi re connectors from the wi ndshi el d
and rear wi ndow washer pumps (Fi g. 3).
(5) I f washer bottl e has fl ui d i n i t pl ace a sui tabl e
drai n pan under the hose connecti ons.
Fig. 1 Windshield Wiper and WasherMulti-Function
Switch Test
Fig. 2 Turn Signal Multi-Function Switch
Fig. 3 Windshield Washer Bottle
(6) Di sconnect front washer hose at front wi per
uni t i n the engi ne compartment (Fi g. 4). The front
hose wi l l be removed wi th the bottl e.
(7) Di sconnect hose from rear washer pump ni ppl e
(Fi g. 5).
(8) Al l ow washer bottl e to drai n.
(9) Remove screws hol di ng washer bottl e to front
fender support and remove bottl e.
INSTALLATION
WINDSHIELD WIPER BLADE
REMOVAL
(1) Li ft the wi per arm away from wi ndshi el d.
(2) Di sengage the rel ease tab hol di ng the wi per
bl ade to the wi per arm and remove the wi per bl ade
from the wi per arm (Fi g. 6).
(3) Remove the wi per bl ade from the wi per arm.
INSTALLATION
Fig. 5 Rear Washer Hose Routing
Fig. 4 Front Washer Hose
Fig. 6 Windshield Wiper Blade
WINDSHIELD WIPER BLADE ELEMENT
REMOVAL
(1) Di sengage the rel ease tab hol di ng the wi per
bl ade to the wi per arm and remove the wi per bl ade
from the wi per arm (Fi g. 6).
(2) Di sengage cl i p hol di ng the wi per el ement to
wi per bl ade (Fi g. 7).
(3) Pul l the el ement from the cl aws on the wi per
bl ade.
INSTALLATION
(1) I nsert the el ement vertebra (Fi g. 8) i nto cl aw
at the open end of the wi per bl ade and through each
cl aw l ocati on al ong the bl ade.
(2) Engage cl i p to hol d wi per el ement to wi per
bl ade.
(3) Test wi per effecti veness usi ng washer mode
and al i gn i f necessary.
WINDSHIELD WIPER MOTOR
REMOVAL
(1) Remove wi per uni t from vehi cl e.
(2) Remove wi per l i nkage and motor mount pl ate
from wi per uni t.
(3) Di sconnect wi re connectors from back of wi per
motor (Fi g. 16).
(4) Remove wi per l i nkage from motor crank. Do
NOT remove crank from motor.
(5) Remove bol ts hol di ng wi per motor to mount
pl ate and remove motor (Fi g. 9) and (Fi g. 10).
INSTALLATION
(1) Pl ace wi per uni t on a sui tabl e work surface.
(2) Pl ace wi per motor i n posi ti on on mount pl ate.
(3) I nstal l bol ts to hol d wi per motor to mount
pl ate.
(4) I nstal l wi per l i nkage and motor mount pl ate
i nto wi per uni t.
(5) Connect wi re connectors to wi per motor (Fi g.
16).
(6) Pl ace the wi per uni t i nto engi ne compartment
and connect wi per uni t wi re connector to engi ne wi re
harness (Fi g. 13).
(7) Operate wi per motor and veri fy that the wi per
motor parks when wi per swi tch i s turned OFF.
Fig. 7 Windshield Wiper Blade Element
Fig. 8 Wiper Blade and Element
Fig. 9 Wiper Motor Crank
Fig. 10 Wiper Motor
WIPER ARM
CAUTION: The Driver side wiper arm must be parked
above the passenger side. Failure to do so will result
in damage to the arms, blades, or system.
REMOVAL
(1) Di sengage the cl i p hol di ng outsi de end of the
wi per arm pi vot cover to the wi per arm.
(2) Li ft the arm cap upward.
(3) Remove the nut hol di ng wi per arm to the wi per
pi vot.
(4) Usi ng a sui tabl e two jaw pul l er, separate the
wi per arm from the wi per pi vot (Fi g. 11).
INSTALLATION
(1) Veri fy that the wi per motor and l i nkage are i n
the park posi ti on.
(2) Pl ace the wi per arm i n posi ti on over the wi per
pi vot (Fi g. 12). Refer to Al i gnment.
(3) I nstal l the nut to hol d the wi per arm to the
wi per pi vot. Ti ghten nut to 35 Nm (26 ft. l bs.).
(4) Push the arm cap cover down.
(5) Engage cl i p to the hol d outsi de end of wi per
arm pi vot cover to the wi per arm.
WIPER UNIT
REMOVAL
(1) Remove the wi per arms.
(2) Remove the cowl cover. Refer to Group 23 Body
for proper procedure.
(3) Rel ease the hood l atch and open hood.
(4) Di sconnect the posi ti ve l ock on the wi per uni t
wi re connector (Fi g. 13).
(5) Di sconnect the wi per uni t wi re connector from
the engi ne compartment wi re harness.
(6) Di sconnect the wi ndshi el d washer hose from
coupl i ng i nsi de uni t.
(7) Di sconnect the drai n tubes from ni ppl es on bot-
tom of the wi per uni t.
(8) Remove nuts hol di ng wi per uni t to l ower wi nd-
shi el d fence.
(9) Remove bol ts hol di ng the wi per uni t to the
dash panel (Fi g. 14).
(10) Li ft wi per uni t from wel d-studs on l ower
wi ndshi el d fence.
CAUTION: Do not allow wiper unit to rest on brake
master cylinder reservoir, damage to brake system
can result.
(11) Remove wi per uni t.
INSTALLATION
WIPER LINKAGE
REMOVAL
(1) Remove the wi ndshi el d wi per uni t from vehi cl e.
Fig. 11 Wiper Arm Removal
Fig. 12 Wiper Arm Adjustment
Fig. 13 Wiper Unit Wire Connector
(2) Pl ace the wi per uni t on a sui tabl e work sur-
face.
(3) Remove nuts hol di ng the cowl cover brackets to
the wi per uni t.
(4) Remove cowl cover brackets from the wi per
uni t.
(5) Remove nuts hol di ng l i nkage and motor mount
pl ate to the wi per uni t (Fi g. 15).
(6) Remove the wi per l i nkage from the wi per uni t.
the wi per motor (Fi g. 16).
INSTALLATION
WIPER BLADES
Wi per bl ades exposed to the weather for a l ong
peri od of ti me tend to l ose thei r wi pi ng effecti veness.
Peri odi c cl eani ng of the wi per bl ade i s recommended
to remove the accumul ati on of sal t and road gri me.
The wi per bl ades, arms and wi ndshi el d shoul d be
cl eaned wi th a sponge or cl oth and a mi l d detergent
or nonabrasi ve cl eaner. I f the wi per bl ades conti nue
to streak or smear, they shoul d be repl aced. The
wi per bl ade shoul d run smoothl y across the wi nd-
shi el d i n both di recti ons. The wi per bl ade shoul d
sl i ghtl y rol l over center when the bl ade reverses
di recti on. A wi per bl ade i nsert that has l ost fl exi bi l i ty
or a wi per arm that has l ost spri ng tensi on, wi l l
cause the bl ade to ski p or chatter across the wi nd-
shi el d. I f the wi per bl ades are new and the wi per
arm spri ng tensi on i s OK and a chatteri ng sound i s
emi tted from the wi per(s), the wi per bl ade i s not rol l -
i ng over center. I f thi s condi ti on exi sts, refer to the
Wi per Arm Al i gnment paragraph of thi s group.
ADJ USTMENTS
WIPER ARM ALIGNMENT
(1) Veri fy wi per bl ade el ement condi ti on and wi per
arm spri ng tensi on. Run wi pers i n l ow speed mode
whi l e appl yi ng water to the wi ndshi el d. Observe the
wi per bl ade that i s chatteri ng or ski ppi ng across the
wi ndshi el d. I f the wi per el ement i s not rol l i ng over
when the wi per di recti on reverses, al i gn the wi per arm.
The extensi on bar porti on of the wi per arm must be
twi sted i n the proper di recti on to al l ow the wi per el e-
ment to rol l over when the di recti on reverses.
(2) Pl ace two smal l adjustabl e wrenches pl aced 50
mm (2 i n.) apart on the wi per arm extensi on rod.
(3) Twi st the extensi on rod sl i ghtl y i n the opposi te
di recti on that the el ement i s l ayi ng on the wi nd-
shi el d whi l e hol di ng the wrench cl osest to the pi vot
stati onary.
(4) Repeat step Step 1, and al i gn as necessary
unti l wi per stops chatteri ng and wi pes the wi nd-
shi el d cl ear.
Fig. 14 Wiper Unit
Fig. 15 Wiper Linkage
Fig. 16 Wiper Motor Connector
REAR WIPER AND WASHER
INDEX
page page
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . 9
REAR WINDOW WIPER/WASHER SWITCHES . . . 9
REAR GLASS RUBBER GROMMET . . . . . . . . . . . 9
REAR WINDOW WIPER MOTOR . . . . . . . . . . . . 10
REAR WIPER ARM . . . . . . . . . . . . . . . . . . . . . . 10
REAR WIPER BLADE ELEMENT . . . . . . . . . . . . 10
REAR WIPER BLADE . . . . . . . . . . . . . . . . . . . . . 10
INTRODUCTION
When conti nuous rear wi per operati on i s requi red,
the Body Control Modul e (BCM) wi l l provi de i gni ti on
ON vol tage to the rear wi per motor. When the wi per
swi tch i s turned OFF, the BCM provi des ci rcui t
ground to operate the motor unti l the wi pe cycl e i s
compl ete and the wi per arm returns to the base of
the rear wi ndow.
When i ntermi ttent rear wi per mode i s sel ected, the
wi per motor wi l l cycl e every 7 seconds. The i ntermi t-
tent del ay ti me i s al so adjusted based upon vehi cl e
speed. Wi th the vehi cl e travel i ng greater at 50 mph,
the cycl e changes to every 5 seconds.
REAR WINDOW WIPER/WASHER SWITCHES
The rear wi ndow wi per/washer swi tches are i ncor-
porated i nto the HVAC swi tch panel . Refer to Group
8E, I nstrument Panel for proper servi ce procedures.
The rear wi ndow wi per system operates i n several
modes:
Conti nuous wi pe
I ntermi ttent wi pe
Wash
Wi pe after wash
The wi ndshi el d wi per ci rcui ts are conti nuousl y
moni tored and control l ed by the Body Control Mod-
ul e (BCM). I f a probl em occurs i n the el ectroni c com-
ponents, wi ri ng, swi tch (except i ntegral motor park
swi tch) and wi per motor a Di agnosti c Troubl e Code
(DTC) wi l l be stored i n the BCM memory. The
DTC(s) can be retri eved usi ng a scan tool (DRB).
Refer to proper Body Di agnosti c Procedures manual
for DTC descri pti ons and retri eval i nformati on.
REAR GLASS RUBBER GROMMET
REMOVAL
(1) Remove rear wi ndow wi per motor.
(2) Peel wi per pi vot seal grommet from rear gl ass.
(3) Remove grommets from vehi cl e (Fi g. 1).
INSTALLATION
Fig. 1 Rear Glass Rubber Grommet
Fig. 2 Rear Glass Rubber Grommets
REAR WINDOW WIPER MOTOR
REMOVAL
(1) Remove rear wi per arm.
(2) Open l i ftgate.
(3) Remove l i ftgate tri m panel .
(4) Di sconnect wi re connector from rear wi per
motor.
(5) Remove screws hol di ng rear wi per motor to l i ft-
gate (Fi g. 3).
(6) Remove wi per motor from l i ftgate.
INSTALLATION
REAR WIPER ARM
REMOVAL
(1) Li ft and hol d wi per bl ade away from rear wi n-
dow.
(2) Li ft l ock hol di ng wi per arm to wi per pi vot
upward.
(3) Al l ow wi per arm to rest agai nst l ock.
(4) Pul l wi per from pi vot (Fi g. 4).
INSTALLATION
REAR WIPER BLADE
REMOVAL
(1) Li ft wi per bl ade away from rear wi ndow.
(2) Rel ease l atch hol di ng bl ade to wi per arm (Fi g.
5).
(3) Remove bl ade from wi per arm.
INSTALLATION
REAR WIPER BLADE ELEMENT
Refer to Wi ndshi el d Wi per Bl ade El ement i n thi s
secti on.
Fig. 3 Rear Window Wiper Motor
Fig. 4 Rear Wiper Arm
Fig. 5 Rear Wiper Arm
WIPER AND WASHER SYSTEMS
CONTENTS
page page
HEADLAMP WASHERS . . . . . . . . . . . . . . . . . . . 1
HEADLAMP WASHERS
INDEX
page page
GENERAL INFORMATION
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . 1
HEADLAMP WASHER NOZZLE . . . . . . . . . . . . . 1
HEADLAMP WASHER PUMP . . . . . . . . . . . . . . . 2
WINDSHIELD/HEADLAMP WASHER
RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . . . . 1
GENERAL INFORMATION
INTRODUCTION
Headl amp washers are avai l abl e as a factory-i n-
stal l ed opti on on thi s model . The headl amp washers
on thi s vehi cl e work i n conjuncti on wi th the wi nd-
shi el d washers. The headl amp washers are enabl ed
wi th the headl amps ON and the wi ndshi el d wash-
ers acti vated. Wi th the wi ndshi el d washers acti vated
the headl amp washers wi l l spray for a preset amount
of ti me control l ed by a rel ay.
The headl amp washer system uti l i zes a separate pump
that i s attached to the wi ndshi el d washer reservoi r. The
headl amp washer pump feeds two nozzl es that are
mounted i n the front fasci a of the vehi cl e. These nozzl es
spray the headl amps when the system i s acti vated.
WINDSHIELD/HEADLAMP WASHER RESERVOIR
Removal
(1) Remove the ri ght headl amp assembl y. Refer to
Group 8L, Lamps.
(2) Parti al l y remove the i nner fender wel l as
needed to gai n access to the reservoi r.
(3) Di sconnect the wi ndshi el d washer pump, rear
washer pump and headl amp washer pump el ectri cal con-
nectors.
(4) Di sconnect the headl amp washer pump hose.
(5) Parti al l y remove the front fasci a to ai d i n the
removal of the reservoi r.
(6) Remove the reservoi r mounti ng bol ts. (Fi g. 1)
(7) Sl i de the reservoi r rearward and remove from
the vehi cl e.
Installation
(1) For i nstal l ati on, reverse the above procedures
HEADLAMP WASHER NOZZLE
Removal
(1) Remove the headl amp assembl y. Refer to
Group 8L, Lamps.
(2) Di sconnect the hose at the headl amp washer nozzl e.
(3) Remove the headl amp washer nozzl e retai ni ng
nuts and remove the nozzl e from the front fasci a.
NS/GS WIPER AND WASHER SYSTEMS 8K - 1
Installation
(1) For i nstal l ati on, reverse the above procedures.
HEADLAMP WASHER PUMP
Removal
(1) Remove the ri ght headl amp assembl y. Refer to
Group 8L, Lamps.
(2) Di sconnect the headl amp washer pump el ectri -
cal connector.
(3) Di sconnect the headl amp washer pump hose.
(4) Remove the headl amp washer pump from the
reservoi r.
Installation
Fig. 1 Reservoir Removal
Fig. 2 HeadLamp Washer Nozzle
Fig. 3 Headlamp Washer Pump
8K - 2 WIPER AND WASHER SYSTEMS NS/GS
LAMPS
CONTENTS
page page
BULB APPLICATION . . . . . . . . . . . . . . . . . . . . . . 25
EXTERIOR LAMP BULB SERVICE . . . . . . . . . . . . 9
EXTERIOR LAMP SERVICE . . . . . . . . . . . . . . . . . 14
HEADLAMP ALIGNMENT . . . . . . . . . . . . . . . . . . . 5
INTERIOR LAMPS . . . . . . . . . . . . . . . . . . . . . . . . 18
LAMP DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . 1
LAMP DIAGNOSIS
INDEX
page page
GENERAL INFORMATION
ELECTRONIC DAYTIME RUNNING LIGHT (DRL) . 1
SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . 1
GENERAL INFORMATION
GENERAL INFORMATION
NS vehi cl es use l i ghti ng on the i nteri or and exte-
ri or of the vehi cl e for i l l umi nati ng and i ndi cati ng
purposes. Li ghti ng ci rcui ts are protected by fuses.
Li ghti ng ci rcui ts requi re an overl oad protected power
source, on/off devi ce, l amps and body ground to oper-
ate properl y. Pl asti c l amps requi re a wi re i n the har-
ness to suppl y body ground to the l amp socket.
Repl ace sockets and bul bs that are corroded.
Some of the i nteri or and exteri or l i ghti ng functi ons
are governed by the body control l er. The headl amp,
dome, and the door ajar swi tches provi de si gnal s to
the body control l er. The body control l er i n turn acti -
vates rel ay(s) i n order to provi de ei ther a ground or
feed l i ne to the appropri ate l amp(s).
Wi re connectors can make i ntermi ttent contact or
become corroded. Before coupl i ng wi re connectors,
i nspect the termi nal s i nsi de the connector. Mal e ter-
mi nal s shoul d not be bent or di sengaged from the
i nsul ator. Femal e termi nal s shoul d not be sprung
open or di sengaged from the i nsul ator. Bent and
sprung termi nal s can be repai red usi ng needl e nose
pl i ers and pi ck tool . Corroded termi nal s appear
chal ky or green. Corroded termi nal s shoul d be
repl aced to avoi d recurrence of the probl em symp-
toms.
Begi n el ectri cal system fai l ure di agnosi s by testi ng
rel ated fuses i n the fuse bl ock and power di stri buti on
center. Veri fy that bul bs are i n good condi ti on and
test conti nui ty of the ci rcui t ground. Refer to Group
8W, Wi ri ng Di agrams, for component l ocati on and ci r-
SAFETY PRECAUTIONS
WARNING: EYE PROTECTION SHOULD BE USED
WHEN SERVICING GLASS COMPONENTS. PER-
SONAL INJURY CAN RESULT.
CAUTION: Do not touch the glass of halogen bulbs
with fingers or other possibly oily surface, reduced
bulb life will result.
Do not use bulbs with higher candle power than
indicated in the Bulb Application table at the end of
this group. Damage to lamp and/or Daytime Run-
ning Lamp Module can result.
Do not use fuses, circuit breakers or relays hav-
ing greater amperage value than indicated on the
fuse panel or in the Owners Manual.
When i t i s necessary to remove components to ser-
vi ce another, i t shoul d not be necessary to appl y
excessi ve force or bend a component to remove i t.
Before damagi ng a tri m component, veri fy hi dden
fasteners or captured edges are not hol di ng the com-
ponent i n pl ace.
ELECTRONIC DAYTIME RUNNING LIGHT (DRL)
The Combi nati on Fl asher/DRL i s a modul e provi d-
i ng turn si gnal , hazard warni ng, and dayti me run-
NS LAMPS 8L - 1
ni ng l i ght functi ons (for Canadi an vehi cl es), and has
been desi gned wi th i nternal rel ays to take advantage
of l ow current swi tchi ng requi rements i n the vehi cl e.
I t i s pl ugged i nto the juncti on bl ock at posi ti ons
three and four (Fi g. 1), where al l wi ri ng associ ated
wi th i ts operati on i s termi nated. The juncti on bl ock
i s adjacent to and l eft of the steeri ng col umn of the
vehi cl e. For di agnosti c i nformati on refer to Group 8J,
Turn Si gnal and Fl ashers.
On vehi cl es bui l t for use i n the Uni ted States, onl y
posi ti on four i s used. Vehi cl es bui l t for use i n Canada
uti l i ze both posi ti ons three and four.
steeri ng col umn cover and knee bl ocker. Refer to
Group 8E, I nstrument Panel and Gauges.
SYSTEM FUNCTION
The combi nati on-fl asher/DRL may be operated i n
i ts hazard warni ng mode ei ther wi th or wi thout the
i gni ti on ci rcui t bei ng acti ve. However, i n order to
operate i n the turn si gnal mode or the DRL mode,
the i gni ti on ci rcui t must be compl eted to the modul e.
Whi l e the combi nati on-fl asher porti on i s i dl e, there
i s no current drawn through the modul e. The devi ce
does not become acti ve i n the turn si gnal or hazard
warni ng modes unti l a si gnal ground ci rcui t i s sup-
pl i ed to ei ther of the turn si gnal i nputs or the hazard
warni ng i nput. Wi th the i gni ti on OFF, there i s no
current drawn through the modul e.
Whi l e the i gni ti on i s ON, the front turn si gnal fi l -
aments are i l l umi nated steadi l y thus provi di ng the
DRL functi on. The DRL functi on may be i nhi bi ted by
appl yi ng a si gnal ground i nput from ei ther the park
brake ci rcui t or the headl amp rel ay acti vati on ci rcui t.
When a vehi cl e experi ences probl ems wi th the
headl amp system, veri fy the condi ti on of the battery
connecti ons, chargi ng system, headl amp bul bs, wi re
connectors, rel ay, hi gh beam di mmer swi tch and
headl amp swi tch. Refer to Group 8W, Wi ri ng Di a-
grams, for component l ocati ons and ci rcui t i nforma-
ti on.
Fig. 1 Junction Block Terminal PINS
8L - 2 LAMPS NS
HEADLAMP DIAGNOSIS
HEADLAMPS ARE DIM
WITH ENGINE IDLING OR
IGNITION TURNED OFF
1. Loose or corroded battery cables. 1. Clean and secure battery cable clamps
and posts.
2. Loose or worn generator drive belt. 2. Adjust or replace generator drive belt.
3. Charging system output too low. 3. Test and repair charging system. Refer to
Group 8A.
4. Battery has insufficient charge. 4. Test battery state-of -charge. Refer to
Group 8A.
5. Battery is sulfated or shorted. 5. Load test battery. Refer to Group 8A.
6. Poor lighting circuit Z1-ground. 6. Test for voltage drop across Z1-ground
locations. Refer to Group 8W.
7. Low beam headlamp / foglamp fuse
blown.
7. Locate cause of blown fuse and repair.
HEADLAMP BULBS BURN
OUT FREQUENTLY
1. Charging system output too high. 1. Test and repair charging system. Refer to
Group 8A.
2. Loose or corroded terminals or
splices in circuit.
2. Inspect and repair all connectors and
splices. Refer to Group 8W.
HEADLAMPS ARE DIM
WITH ENGINE RUNNING
ABOVE IDLE
1. Charging system output too low. 1. Test and repair charging system. Refer to
Group 8A.
3. High resistance in headlamp circuit. 3. Test amperage draw of headlamp circuit.
4. Low beam headlamp / fog lamp
fuse blown.
4. Locate cause of blown fuse and repair.
HEADLAMPS FLASH
RANDOMLY
locations, refer to Group 8W.
2. High resistance in headlamp circuit. 2. Test amperage draw of headlamp circuit.
splices in circuit.
HEADLAMPS DO NOT
ILLUMINATE
1. No voltage to headlamps. 1. Repair open headlamp circuit. Refer to
Group 8W.
2. No Z1-ground at headlamps. 2. Repair circuit ground. Refer to Group 8W.
3. Faulty headlamp switch. 3. Replace headlamp switch.
4. Faulty headlamp dimmer (multi-
function) switch.
4. Replace multi-function switch.
5. Broken connector terminal or wire
splice in headlamp circuit.
5. Repair connector terminal or wire splice.
6. Defective or burned out bulb. 6. Replace bulb.
7. Body controller malfunction. 7. Refer to appropriate body controller
diagnostics.
NS LAMPS 8L - 3
FOG LAMP DIAGNOSIS
FOG LAMPS ARE DIM WITH
ENGINE IDLING OR IGNITION
TURNED OFF.
1. Loose or corroded battery
cables.
1. Clean and secure battery cable
clamps and posts.
2. Loose or worn generator drive
belt.
2. Adjust or replace generator drive
belt.
3. Charging system output too low. 3. Test and repair charging system.
Refer to Group 8A,
4. Battery has insufficient charge. 4. Test battery state-of -charge.
Refer to Group 8A.
5. Battery is sulfated or shorted. 5. Load test battery. Refer to Group
8A.
6. Poor lighting circuit Z1-ground. 6. Test for voltage drop across
Z1-ground locations. Refer to Group
8W.
FOG LAMP BULBS BURN OUT
FREQUENTLY
1. Charging system output too high. 1. Test and repair charging system.
Refer to Group 8A.
splices in circuit.
2. Inspect and repair all connectors
and splices. Refer to Group 8W.
ENGINE RUNNING ABOVE IDLE
Refer to Group 8A.
8W.
3. High resistance in fog lamp
circuit.
3. Test amperage draw of fog lamp
circuit.
FOG LAMPS FLASH RANDOMLY 1. Poor lighting circuit Z1-ground. 1. Test for voltage drop across
8W.
circuit.
circuit.
3. Faulty fog lamp switch. 3. Replace fog lamp switch.
splices in circuit.
FOG LAMPS DO NOT ILLUMINATE 1. Blown fuse for fog lamp. 1. Replace fuse. Refer to Group
8W.
2. No Z1-ground at fog lamps. 2. Repair circuit ground. Refer to
Group 8W.
4. Broken connector terminal or
wire splice in fog lamp circuit.
4. Repair connector terminal or wire
splice.
8L - 4 LAMPS NS
HEADLAMP ALIGNMENT
INDEX
page page
GENERAL INFORMATION
HEADLAMP ALIGNMENT . . . . . . . . . . . . . . . . . . . 5
SERVICE PROCEDURES
HEADLAMP ALIGNMENT PREPARATION . . . . . . . 5
ADJUSTMENTS
HEADLAMP/FOG LAMP ADJUSTMENT USING
ALIGNMENT SCREEN . . . . . . . . . . . . . . . . . . . . 5
GENERAL INFORMATION
HEADLAMP ALIGNMENT
The headl amps are equi pped wi th a bubbl e l evel
for up/down headl amp al i gnment. The bubbl e i s cen-
tered wi th the vehi cl e on a l evel surface. A hori zontal
gauge and magni fyi ng wi ndow i s l ocated next to the
bubbl e l evel for l eft/ri ght al i gnment (Fi g. 1). Ai m on
every headl amp assembl y i s cal i brated at the head-
l amp manufacturer. At the vehi cl e assembl y pl ant,
the verti cal ai m i s set by centeri ng the bubbl e wi th
the vehi cl e on a l evel surface. Hori zontal ai m i s con-
trol l ed by the mounti ng pads on each headl amp
mounti ng panel .
When the vehi cl e i s to be used wi th a heavy l oad,
the bubbl e l evel can be used to compensate for the
al tered ri de hei ght.
SERVICE PROCEDURES
HEADLAMP ALIGNMENT PREPARATION
(1) Veri fy headl amp di mmer swi tch and hi gh beam
i ndi cator operati on.
(2) I nspect and correct damaged or defecti ve com-
ponents that coul d i nterfere wi th proper headl amp
al i gnment.
(3) Veri fy proper ti re i nfl ati on.
(4) Cl ean headl amp l enses.
(5) Veri fy that l uggage area i s l oaded as the vehi -
cl e i s routi nel y used.
(6) Fuel tank shoul d be FULL. Add 2.94 kg (6.5
l bs.) of wei ght over the fuel tank for each esti mated
gal l on of mi ssi ng fuel .
ADJ USTMENTS
ALIGNMENT SCREEN
ALIGNMENT SCREEN PREPARATION
(1) Posi ti on vehi cl e on a l evel surface perpendi cu-
l ar to a fl at wal l 7.62 meters (25 ft.) away from front
of headl amp l ens (Fi g. 2).
(2) I f necessary, tape a l i ne on the fl oor 7.62
meters (25 ft.) away from and paral l el to the wal l .
(3) From the fl oor up 1.27 meters (5 ft.), tape a
l i ne on the wal l at the center l i ne of the vehi cl e.
Si ght al ong the center l i ne of the vehi cl e (from rear
of vehi cl e forward) to veri fy accuracy of the l i ne
pl acement.
(4) Rock vehi cl e si de-to-si de three ti mes and al l ow
suspensi on to stabi l i ze.
(5) Jounce front suspensi on three ti mes by pushi ng
downward on front bumper and rel easi ng.
(6) Measure the di stance from the center of head-
l amp l ens to the fl oor. Transfer measurement to the
al i gnment screen (wi th tape). Use thi s l i ne for
up/down adjustment reference.
(7) Measure di stance from the center l i ne of the
vehi cl e to the center of each headl amp bei ng al i gned.
Transfer measurements to screen (wi th tape) to each
Fig. 1 Magnifying Window and Bubble Level
NS LAMPS 8L - 5
si de of vehi cl e center l i ne. Use these l i nes for l eft/
ri ght adjustment reference.
HEADLAMP ADJ USTMENT
A properl y ai med l ow beam headl amp wi l l project
the center of the l ow beam hot spot on the al i gnment
screen 229 mm (9 i n.) 50 mm (2 i n.) bel ow the
headl amp center l i ne. The center of the hot spot
shoul d be 100 mm (4 i n.) 50 mm (2 i n.) ri ght of the
headl amp center l i ne (Fi g. 2). The hi gh beams on a
vehi cl e wi th aero headl amps cannot be al i gned. The
hi gh beam pattern shoul d be correct when the l ow
beams are al i gned properl y.
To adjust headl amp al i gnment, rotate adjusti ng
screws to achi eve the speci fi ed l ow beam hot spot
l ocati on (Fi g. 3).
HEADLAMP ADJ USTMENT TOWN AND
COUNTRY
A properl y ai med l ow beam headl amp wi l l project
the center of the l ow beam hot spot on the al i gnment
screen 152 mm (6 i n.) 50 mm (2 i n.) bel ow the
headl amp center l i ne. The center of the hot spot
shoul d be 254 mm (10 i n.) 50 mm (2 i n.) ri ght of
the headl amp center l i ne (Fi g. 4). The hi gh beams on
a vehi cl e wi th aero headl amps cannot be al i gned. The
Fig. 2 Headlamp Alignment Screen
Fig. 3 Headlamp Bubble Level and Adjusters
8L - 6 LAMPS NS
To adjust headl amp al i gnment, rotate adjusti ng
l ocati on (Fi g. 3).
BUBBLE LEVEL CALIBRATION
(VERTICAL AIM)
After the headl amp al i gnment has been veri fi ed or
set and the bubbl e l evel i s not centered, cal i brate the
bubbl e l evel .
NOTE: Any calibration of the headlamp bubble
level must be done on a level surface and the head-
lamp cool. Do not operate the headlamps for a min-
imum of 20 minutes prior to beginning adjustments.
(1) Remove screws hol di ng magni fyi ng wi ndow to
top of headl amp modul e (Fi g. 5).
(2) Posi ti on magni fyi ng wi ndow to the si de
between headl amp modul e and radi ator cl osure
panel .
(3) Through sl otted hol e i n magni fyi ng wi ndow,
i nsert smal l screw dri ver i nto bubbl e l evel cal i brati on
screw.
(4) Rotate cal i brati on screw i n proper di recti on
unti l bubbl e i s centered on the O.
(5) I nstal l magni fyi ng wi ndow, maki ng sure O-ri ng
seal i s i n pl ace.
(6) I f necessary, cal i brate magni fyi ng wi ndow.
MAGNIFYING WINDOW CALIBRATION
(HORIZONTAL AIM)
After the headl amp al i gnment has been veri fi ed or
set and the magni fyi ng wi ndow i s not centered, cal i -
brate the magni fyi ng wi ndow.
(1) Loosen screws hol di ng magni fyi ng wi ndow to
top of headl amp modul e (Fi g. 5).
(2) Usi ng the cal i brati on knob above headl amp
l ens, rotate magni fyi ng wi ndow unti l wi ndow i s cen-
tered over the O on the gauge bel ow the wi ndow.
Fig. 4 Headlamp Alignment Screen T&C
NS LAMPS 8L - 7
(3) Ti ghten screws to hol d magni fyi ng wi ndow to
headl amp modul e. Do not over ti ghten.
FOG LAMP ALIGNMENT
Prepare an al i gnment screen. Refer to the Al i gn-
ment Screen Preparati on paragraph i n thi s secti on. A
properl y al i gned fog l amp wi l l project a pattern on
the al i gnment screen 100 mm (4 i n.) bel ow the fog
l amp center l i ne and strai ght ahead (Fi g. 6). To
i mprove vi sual i nterpretati on of the fog l amp pattern
on the al i gnment screen, di sabl e the headl amps by
di sengagi ng the wi re connectors from the headl amp
bul bs.
The Town and Country fog l amp adjustment screw
i s l ocated through the l ens (Fi g. 7).
Fig. 6 Fog Lamp Alignment
Fig. 5 Magnifying Window and Bubble Level
Calibration
Fig. 7 Fog Lamp Adjustment Screw
8L - 8 LAMPS NS
EXTERIOR LAMP BULB SERVICE
INDEX
page page
CENTER HIGH MOUNTED STOP LAMP
(CHMSL) BULB . . . . . . . . . . . . . . . . . . . . . . . . 13
FOG LAMP BULB TOWN and COUNTRY . . . . . 11
FOG LAMP BULB . . . . . . . . . . . . . . . . . . . . . . . . 10
FRONT PARKING AND TURN SIGNAL LAMP
BULB TOWN and COUNTRY . . . . . . . . . . . . 12
FRONT SIDE MARKER LAMP BULB TOWN and
COUNTRY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
HEADLAMP BULB TOWN & COUNTRY . . . . . . . 9
HEADLAMP BULB . . . . . . . . . . . . . . . . . . . . . . . . 9
LICENSE PLATE LAMP BULB . . . . . . . . . . . . . . 13
PARKING AND TURN SIGNAL BULB . . . . . . . . . 11
TAIL, STOP, TURN SIGNAL AND BACK-UP
LAMP BULB . . . . . . . . . . . . . . . . . . . . . . . . . . 12
HEADLAMP BULB
REMOVAL
(2) From behi nd radi ator cl osure panel , di sconnect
wi re connector from back of headl amp bul b base.
(3) Rotate headl amp bul b retai ni ng ri ng counter-
cl ockwi se.
(4) Remove retai ni ng ri ng from headl amp (Fi g. 1).
(5) Pul l headl amp bul b from back of headl amp.
INSTALLATION
(1) From behi nd radi ator cl osure panel , i nsert
headl amp bul b i nto back of headl amp.
(2) Engage retai ni ng ri ng onto headl amp (Fi g. 1).
(3) Rotate headl amp bul b retai ni ng ri ng cl ockwi se.
(4) Connect wi re connector i nto headl amp bul b
base.
(5) Veri fy headl amp al i gnment.
HEADLAMP BULB TOWN & COUNTRY
HEADLAMP HIGH BEAM
REMOVAL
(2) From behi nd radi ator cl osure panel , di sconnect
wi re connector from back of hi gh headl amp bul b
base.
(3) Rotate headl amp bul b countercl ockwi se and
pul l bul b from back of headl amp modul e (Fi g. 2).
INSTALLATION
(1) I nsert bul b i nto the back of the headl amp mod-
ul e.
(2) Rotate headl amp bul b cl ockwi se to engage
bul b.
(3) Connect wi re connector to the l ow beam head-
l amp. Veri fy headl amp bul b operati on
HEADLAMP LOW BEAM
REMOVAL
(2) Remove the three headl amp mounti ng nuts.
(3) Remove one attachi ng screw on top of the
crossmember.
(4) Di sconnect wi re connector from the back of the
l ow beam headl amp bul b base (Fi g. 4).
Fig. 1 Headlamp Bulb
NS LAMPS 8L - 9
(5) Rotate headl amp bul b retai ner countercl ock-
wi se and di sengage retai ner from headl amp (Fi g. 3).
(6) Pul l headl amp bul b from back of the headl amp
modul e.
INSTALLATION
(1) Pl ace headl amp bul b i nto headl amp modul e.
(2) Rotate headl amp bul b retai ner cl ockwi se to
engage retai ner.
(3) Connect wi re connector to the l ow beam head-
l amp. Veri fy headl amp bul b operati on
(4) I nstal l the headl amp modul e.
FOG LAMP BULB
REMOVAL
(1) Remove fog l amp from vehi cl e.
(2) Remove rear cover from fog l amp.
(3) Di sengage wi re cl i p hol di ng bul b i n fog l amp
(Fi g. 5).
(4) Hi nge wi re retai ner cl i p out of bul b removal
path.
(5) Pul l bul b from l amp.
(6) Di sconnect wi re connector from fog l amp wi re
harness.
INSTALLATION
with fingers or other oily surfaces, reduced bulb life
will result.
Fig. 2 Headlamp High Beam Bulb T&C
Fig. 3 Low Beam Headlamp Retainer
Fig. 4 Headlamp Low Beam Bulb T&C
Fig. 5 Fog Lamp Bulb
8L - 10 LAMPS NS
(1) Connect wi re connector i nto fog l amp wi re har-
ness.
(2) I nsert bul b i nto l amp so i ndex notches on bul b
engage wi th bosses i n l amp (Fi g. 5).
(3) Hi nge wi re retai ner cl i p over bul b base.
(4) Engage wi re cl i p to hol d bul b i nto l amp.
(5) I nstal l rear cover on fog l amp.
(6) I nstal l fog l amp on vehi cl e.
FOG LAMP BULB TOWN and COUNTRY
REMOVAL
(1) Reach behi nd fasci a and remove bul b by rotat-
i ng countercl ockwi se (Fi g. 6).
(2) Rotate l amp bul b countercl ockwi se to di sengage
bul b.
(3) Di sconnect the wi re connector from fog l amp
bul b base.
(4) Repl ace bul b.
INSTALLATION
will result.
(1) Connect wi re connector i nto fog l amp bul b
base.
(2) I nsert bul b i nto fog l amp housi ng.
(3) Rotate l amp bul b cl ockwi se to engage bul b.
(4) Veri fy bul b operati on.
(5) Veri fy fog l amp al i gnment.
FRONT SIDE MARKER LAMP BULB TOWN and
COUNTRY
REMOVAL
(1) Remove screw attachi ng si de marker l amp to
fasci a.
(2) Remove housi ng by pul l i ng rearward and away
from fasci a (Fi g. 7).
(3) Rotate l amp socket countercl ockwi se one quar-
ter turn.
(4) Pul l bul b socket from the rear of l amp (Fi g. 8).
INSTALLATION
(1) I nsert bul b i nto socket.
(2) I nsert bul b socket i nto rear of housi ng.
(3) Rotate park and turn si gnal socket cl ockwi se
one quarter turn.
(4) Veri fy bul b operati on.
(5) I nstal l screw attachi ng si de marker l amp.
PARKING AND TURN SIGNAL BULB
REMOVAL
(1) From under front wheel house, remove access
cover behi nd parki ng and turn si gnal l amp.
(2) Through access hol e i n wheel house, rotate
parki ng and turn si gnal socket countercl ockwi se one
quarter turn.
(3) Pul l socket from back of l amp (Fi g. 9).
INSTALLATION
(1) Al i gn key on bul b base to groove i n socket and
i nsert bul b i nto socket.
Fig. 6 Fog Lamp Bulb T&C
Fig. 7 Front Side Marker Lamp Bulb T&C
Fig. 8 Front Side Marker Lamp Sockets
NS LAMPS 8L - 11
(2) Through access hol e i n wheel house, i nsert
socket i nto back of l amp.
(3) Rotate parki ng and turn si gnal socket cl ock-
wi se one quarter turn.
(4) I nstal l access cover and veri fy l amp operati on.
FRONT PARKING AND TURN SIGNAL LAMP BULB
TOWN and COUNTRY
REMOVAL
(1) Remove screw attachi ng si de marker l amp to
fasci a.
(2) Remove housi ng by pul l i ng outward and away
from the fasci a (Fi g. 10).
(3) Remove screw attachi ng parki ng and turn si g-
nal l amp housi ng.
(4) Rotate l amp socket(s) countercl ockwi se one
quarter turn (Fi g. 11).
(5) Pul l bul b socket(s).
(6) Pul l bul b from socket(s).
INSTALLATION
(2) I nsert bul b socket i nto housi ng.
(4) Veri fy bul b(s) operati on.
(5) I nstal l screw attachi ng parki ng and turn si gnal
l amp housi ng.
TAIL, STOP, TURN SIGNAL AND BACK-UP LAMP
BULB
REMOVAL
(1) Rel ease l i ftgate l atch and open l i ftgate.
(2) Remove screws hol di ng tai l , stop, turn si gnal
and back-up l amp to rear door openi ng trough.
(3) Remove i nner end of l amp from quarter panel .
(4) Di sengage hook hol di ng outer end of l amp to
quarter panel openi ng.
(5) Remove l amp from quarter panel .
(7) Pul l socket from back of l amp.
(8) Pul l bul b from socket (Fi g. 13).
INSTALLATION
i nsert bul b i nto socket (Fi g. 13).
(2) I nsert socket i nto back of l amp.
(3) Rotate l amp socket cl ockwi se one quarter turn.
(4) Engage hook to hol d outer end of l amp to quar-
ter panel openi ng.
(5) Pl ace l amp i n posi ti on on quarter panel .
(6) I nstal l screws to hol d l amp to rear door open-
i ng trough.
(7) Veri fy tai l , stop, turn si gnal and back-up l amp
operati on.
Fig. 9 Parking and Turn Signal Lamp Bulb
Fig. 10 Front Parking and Turn Signal Lamp T&C
Fig. 11 Front Parking and
Turn Signal Lamp Bulb(s) T&C
8L - 12 LAMPS NS
LICENSE PLATE LAMP BULB
REMOVAL
(1) Remove screws attachi ng l i cense pl ate l amp
l ens to l i ftgate.
(2) Remove l i cense pl ate l amp l ens from l amp.
ter turn.
(4) Pul l socket from l ens (Fi g. 14).
INSTALLATION
(1) I nstal l bul b i nto socket.
(2) I nsert socket i nto l ens.
(3) Rotate l amp socket cl ockwi se one quarter turn.
(4) Pl ace l i cense pl ate l amp l ens i n posi ti on i n
l amp.
(5) I nstal l screws attachi ng l i cense pl ate l amp
l ens.
(6) Veri fy l i cense pl ate l amp operati on.
(CHMSL) BULB
REMOVAL
(2) Di sengage cl i ps hol di ng CHMSL access tri m
cover to l i ftgate.
(3) Remove tri m cover from l i ftgate.
ter turn.
(5) Pul l socket from l amp (Fi g. 15).
INSTALLATION
(2) I nsert socket i nto l amp.
(3) Rotate bul b socket cl ockwi se one quarter turn.
(4) Pl ace CHMSL access tri m cover i n posi ti on on
l i ftgate.
(5) Engage cl i ps to hol d access cover to l i ftgate.
(6) Veri fy CHMSL operati on.
Fig. 12 Tail, Stop, Turn Signal
and Back-up Lamp Bulb
Fig. 13 Pull Bulb From Socket
Fig. 14 License Plate Lamp Bulb
Fig. 15 CHMSL Bulb
NS LAMPS 8L - 13
EXTERIOR LAMP SERVICE
INDEX
page page
GENERAL INFORMATION
HEADLAMP DIMMER SWITCH . . . . . . . . . . . . . . 14
HEADLAMP MODULE . . . . . . . . . . . . . . . . . . . . 14
HEADLAMP SWITCH . . . . . . . . . . . . . . . . . . . . . 14
(CHMSL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
FOG LAMP TOWN and COUNTRY . . . . . . . . . 15
FOG LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
TOWN and COUNTRY . . . . . . . . . . . . . . . . . . 15
FRONT SIDE MARKER LAMP TOWN and
COUNTRY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
HEADLAMP MODULE . . . . . . . . . . . . . . . . . . . . 14
LICENSE PLATE LAMP . . . . . . . . . . . . . . . . . . . 16
TAIL, STOP, TURN SIGNAL AND BACK-UP
LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
GENERAL INFORMATION
HEADLAMP MODULE
Mi nor amounts of foggi ng may occur around the
edges of the headl amp l ens when exposed to humi d
condi ti ons. Thi s i s consi dered normal . The foggi ng
wi l l di ssi pate wi th i ncreased ambi ent temperature or
headl amp usage.
HEADLAMP SWITCH
Servi ce procedures for the headl amp swi tch can be
found i n Group 8E, I nstrument Panel and Gauges.
More i nformati on can be found i n Group 8W, Wi ri ng
Di agrams.
HEADLAMP DIMMER SWITCH
The headl amp di mmer swi tch i s i ncorporated i nto
the mul ti -functi on (turn si gnal ) swi tch. Proper proce-
dures can be found i n Group 8J, Turn Si gnal and
Fl ashers. More i nformati on can be found i n Group
8W, Wi ri ng Di agrams.
HEADLAMP MODULE
REMOVAL
(2) From i nsi de engi ne compartment, remove nuts
hol di ng headl amp modul e to radi ator cl osure panel .
(3) Remove screw hol di ng top of modul e to cl osure
panel .
(4) Remove headl amp modul e from radi ator cl o-
sure panel (Fi g. 1).
(5) Di sconnect wi re connectors from back of head-
l amp modul e.
(6) Separate headl amp modul e from vehi cl e.
INSTALLATION
(1) Pl ace headl amp modul e i n posi ti on on vehi cl e.
(2) Connect wi re connectors i nto back of headl amp
modul e.
(3) Pl ace headl amp modul e i n posi ti on on radi ator
cl osure panel .
(4) I nstal l nuts to hol d headl amp modul e to radi a-
tor cl osure panel .
(5) I nstal l screw to hol d top of modul e to cl osure
panel .
(6) Veri fy headl amp operati on and al i gnment.
FOG LAMP
REMOVAL
(1) Remove screws hol di ng fog l amp to front
bumper fasci a (Fi g. 2).
(2) Remove fog l amp from fasci a.
(3) Di sconnect wi re connector from body wi re har-
ness.
Fig. 1 Headlamp Module Typical
8L - 14 LAMPS NS
INSTALLATION
(1) Posi ti on fog l amp on vehi cl e.
(2) Connect wi re connector to body wi re harness.
(3) I nstal l fog l amp i nto bumper fasci a.
(4) I nstal l screws to hol d fog l amp to front bumper
fasci a.
FOG LAMP TOWN and COUNTRY
REMOVAL
(1) From behi nd fasci a remove nuts attachi ng fog
l amp housi ng to fasci a (Fi g. 3).
(2) Remove fog l amp from fasci a.
(3) Di sconnect wi re connector from body wi re har-
ness.
(4) Remove fog l amp housi ng from vehi cl e.
INSTALLATION
(1) Connect wi re connector to body wi re harness.
(3) Veri fy fog l amp operati on.
(4) I nsert fog l amp i nto bumper fasci a.
(5) I nstal l nuts attachi ng fog l amp to fasci a.
FRONT SIDE MARKER LAMP TOWN and COUNTRY
REMOVAL
(1) Remove screw attachi ng si de marker l amp.
(2) Remove housi ng by pul l i ng rearward and away
from fasci a (Fi g. 7).
ter turn.
(4) Pul l bul b socket from the rear of l amp (Fi g. 4).
(5) Remove si de marker housi ng from vehi cl e.
INSTALLATION
(1) I nsert bul b socket i nto rear of housi ng.
(2) Rotate park and turn si gnal socket cl ockwi se
one quarter turn.
TOWN and COUNTRY
REMOVAL
(1) Remove screw attachi ng si de marker l amp.
(2) Remove housi ng by pul l i ng outward and away
from the fasci a (Fi g. 10).
Fig. 2 Fog Lamp
Fig. 3 Fog Lamp Bulb T&C
Fig. 4 Front Side Marker Lamp T&C
NS LAMPS 8L - 15
(3) Remove screw attachi ng parki ng and turn si g-
nal l amp housi ng to fasci a.
(4) Rotate l amp socket(s) countercl ockwi se one
quarter turn (Fi g. 11).
(5) Pul l bul b socket(s).
(6) Remove parki ng and turn si gnal l amp housi ng
from vehi cl e (Fi g. 5).
INSTALLATION
(1) I nsert bul b socket i nto housi ng.
(4) I nstal l screw attachi ng parki ng and turn si gnal
l amp housi ng.
TAIL, STOP, TURN SIGNAL AND BACK-UP LAMP
REMOVAL
(2) Remove screws hol di ng tai l , stop, turn si gnal
and back-up l amp to rear door openi ng trough.
(3) Remove i nner end of l amp from quarter panel .
(5) Remove l amp from quarter panel (Fi g. 6).
(6) Di sconnect posi ti ve l ock on wi re connector (Fi g.
7).
(7) Depress l ock tab on the si de of the body har-
ness connector.
(8) Di sconnect wi re connector from tai l l amp ci r-
cui t board.
(9) Remove tai l l amp from vehi cl e.
INSTALLATION
(1) Pl ace tai l l amp i n posi ti on on vehi cl e.
(2) Connect wi re connector i nto tai l l amp ci rcui t
board.
(3) Connect posi ti ve l ock on wi re connector.
(4) Pl ace l amp i n posi ti on i n posi ti on on quarter
panel .
ter panel openi ng.
(6) Posi ti on i nner end of l amp i nto quarter panel .
(7) I nstal l screws to hol d tai l , stop, turn si gnal and
back-up l amp to rear door openi ng trough.
(8) Veri fy tai l l amp operati on.
LICENSE PLATE LAMP
REMOVAL
(2) Remove l i ftgate tri m panel . Refer to Group 23,
Body, for proper procedures.
(3) Remove water shi el d as necessary to gai n
access to back of l i cense pl ate l amp bar.
(4) Di sconnect wi re connector from l i ftgate wi re
harness.
(5) Remove screws hol di ng l i cense pl ate l amp bar
to l i ftgate.
(6) Remove l i cense pl ate l amp bar from l i ftgate
(Fi g. 8).
(7) Remove l i cense pl ate l amp bar from vehi cl e.
Fig. 5 Parking and Turn Signal Lamp Housing
T&C
Fig. 6 Tail, Stop, Turn Signal and Back-up Lamp
Fig. 7 Tail Lamp Connector
8L - 16 LAMPS NS
NOTE: Wire connector may be disconnected at
socket which eliminates removal of liftgate trim.
INSTALLATION
(1) Pl ace l i cense pl ate l amp bar i n posi ti on on l i ft-
gate.
(2) I nstal l screws to hol d l i cense pl ate l amp bar to
l i ftgate.
(3) Connect wi re connector i nto l i ftgate wi re har-
ness.
(4) I nstal l water shi el d.
(5) I nstal l l i ftgate tri m panel .
CENTER HIGH MOUNTED STOP LAMP (CHMSL)
REMOVAL
(2) Di sengage cl i ps hol di ng CHMSL access cover to
l i ftgate.
(3) Remove cover from l i ftgate.
(4) Rotate bul b sockets countercl ockwi se one quar-
ter turn.
(5) Pul l sockets from l amp.
(6) Remove screws hol di ng CHMSL to l i ftgate.
(7) Remove CHMSL from vehi cl e (Fi g. 9).
INSTALLATION
(1) Pl ace CHMSL i n posi ti on on vehi cl e.
(2) I nstal l screws to hol d CHMSL to l i ftgate.
(4) I nsert sockets i nto l amp.
(5) Rotate bul b sockets cl ockwi se one quarter turn.
(6) Pl ace CHMSL access cover i n posi ti on on l i ft-
gate.
(7) Engage cl i ps to hol d access cover to l i ftgate.
Fig. 8 License Plate Lamp
Fig. 9 CHMSL
NS LAMPS 8L - 17
INTERIOR LAMPS
INDEX
page page
CONVENIENCE BIN LAMP . . . . . . . . . . . . . . . . . 20
DOME LAMP BULB . . . . . . . . . . . . . . . . . . . . . . 21
DOME LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
FRONT DOOR COURTESY LAMP BULB . . . . . . 22
FRONT DOOR COURTESY LAMP . . . . . . . . . . . 21
GLOVE BOX LAMP AND SWITCH . . . . . . . . . . . 19
GLOVE BOX LAMP BULB . . . . . . . . . . . . . . . . . . 19
HEADER READING/COURTESY LAMP BULB . . . 19
HEADER READING/COURTESY LAMP . . . . . . . 18
IGNITION HALO LAMP BULB . . . . . . . . . . . . . . . 19
INSTRUMENT PANEL LAMPS AND SWITCHES . 20
LIFTGATE COURTESY LAMP BULB . . . . . . . . . . 24
LIFTGATE COURTESY LAMP . . . . . . . . . . . . . . . 23
OVERHEAD CONSOLE READING/COURTESY
LAMP BULB . . . . . . . . . . . . . . . . . . . . . . . . . . 18
RAIL LAMP MODULE BULB . . . . . . . . . . . . . . . . 23
OVERHEAD CONSOLE READING/COURTESY LAMP
BULB
REMOVAL
(1) Usi ng a tri m sti ck, l i ghtl y pry outward the for-
ward end of readi ng l amp l ens.
(2) Rotate readi ng l amp bul b socket one quarter
turn countercl ockwi se.
(3) Pul l socket out of l amp (Fi g. 1).
INSTALLATION
(1) Push bul b i nto socket.
(2) Push socket i nto l amp.
(3) Rotate readi ng l amp bul b socket one quarter
turn cl ockwi se.
(4) I nsert tab on l amp l ens between l amp swi tch
and overhead consol e.
(5) Snap l ens onto l amp l ens pi vots.
HEADER READING/COURTESY LAMP
REMOVAL
(1) Grasp outer edges of header readi ng/courtesy
l amp at headl i ni ng.
(2) Pul l downward to di sengage cl i ps on readi ng/
courtesy l amp from roof header panel (Fi g. 2).
(3) Di sconnect wi re connector from readi ng/cour-
tesy l amp.
(4) Remove l amp from vehi cl e.
INSTALLATION
(1) Posi ti on l amp on vehi cl e.
(2) Connect wi re connector to readi ng/courtesy
l amp.
(3) Al i gn cl i ps on readi ng/courtesy l amp to mati ng
hol es i n roof header panel .
(4) Push upward to engage cl i ps on readi ng/cour-
tesy l amp to roof header panel .
Fig. 1 Reading/Courtesy Lamp
Fig. 2 Header Reading/Courtesy Lamp
8L - 18 LAMPS NS
HEADER READING/COURTESY LAMP BULB
REMOVAL
(1) I nsert a smal l , fl at bl aded pry tool at forward
posi ti on between readi ng/courtesy l amp l ens and
l amp housi ng.
(2) Pry l amp l ens from l amp housi ng (Fi g. 3).
(3) I nsert a smal l , fl at bl aded pry tool between
l amp l i ght shi el d and l amp housi ng at i nboard rear
corner of l i ght shi el d.
(4) Pry l i ght shi el d from housi ng (Fi g. 4).
(5) Careful l y press forward l amp bul b contact
toward opposi te contact and rotate.
(6) Remove bul b from l amp bul b contacts.
INSTALLATION
(1) Careful l y press forward l amp bul b contact
toward opposi te contact and rotate bul b i nto posi ti on.
(2) Posi ti on bul b to l amp bul b contacts.
(3) Rel ease l amp bul b contacts.
(4) I nsert outer edge of l i ght shi el d i nto l amp
housi ng (Fi g. 4).
(5) Rotate l i ght shi el d upward and snap i nboard
edge i nto l amp housi ng.
(6) Posi ti on l ens swi tch tab to l amp swi tch.
(7) Press l ens pi vots to tabs on l amp housi ng unti l
both pi vots are seated.
REMOVAL
(1) Open gl ove box door.
(3) Di sconnect wi re connector from gl ove box l amp
(Fi g. 5).
(4) Remove gl ove box l amp from vehi cl e.
INSTALLATION
(1) Posi ti on gl ove box l amp i n vehi cl e.
(2) Connect wi re connector from gl ove box l amp.
(3) Posi ti on gl ove box l amp i n i nstrument panel .
(4) Press l amp i nto i nstrument panel unti l ful l y
seated.
GLOVE BOX LAMP BULB
REMOVAL
(1) Remove gl ove box l amp/swi tch from i nstrument
panel .
(2) Pul l bul b from gl ove box l amp (Fi g. 6).
INSTALLATION
(1) Push bul b i nto gl ove box l amp.
(2) I nstal l gl ove box l amp/swi tch i n i nstrument
panel .
IGNITION HALO LAMP BULB
REMOVAL
(1) Remove steeri ng col umn tri m covers. Refer to
Group 19, Steeri ng, for proper procedures.
Fig. 3 Reading/Courtesy Lamp Lens
Fig. 4 Reading/Courtesy Lamp Light Shield
NS LAMPS 8L - 19
ter turn (Fi g. 7).
(3) Pul l bul b socket from hal o l amp.
INSTALLATION
(1) Push bul b socket i nto hal o l amp.
(2) Rotate bul b socket cl ockwi se one quarter turn.
(3) I nstal l steeri ng col umn tri m covers. Refer to
Group 19, Steeri ng, for proper procedures.
CONVENIENCE BIN LAMP
I f the l amp i s not used refer to (Fi g. 8).
REMOVAL
(1) Pul l out the conveni ence bi n cup hol der.
(2) I nsert the tri m sti ck between access cover
above cup hol der and center consol e.
(3) Careful l y pry the access cover from the center
consol e (Fi g. 9).
(4) Remove the access cover from the vehi cl e.
(5) Usi ng needl e-nose pl i ers, careful l y squeeze the
verti cal metal l egs of the l amp hood.
(6) Li ft the l amp hood upward from the cup hol der
tray.
(7) Careful l y pul l the l amp and wi ri ng rearward
from the i nstrument panel (Fi g. 10).
(8) Pul l the l amp hood from the l amp socket.
INSTALLATION
INSTRUMENT PANEL LAMPS AND SWITCHES
For repl acement of i nstrument panel l amps and
swi tches, refer to Group 8E, I nstrument Panel and
Systems.
Fig. 6 Glove Box Lamp Bulb
Fig. 7 Ignition Halo Lamp Bulb
Fig. 8 Wiring for the Convenience Lamp
Fig. 10 Convenience Bin Lamp Bulb
8L - 20 LAMPS NS
DOME LAMP
REMOVAL
dome l amp l ens and dome l amp body on l eft si de of
dome l amp.
(2) Di sengage l eft si de of dome l amp l ens from
l amp body (Fi g. 11).
(3) Pi vot dome l amp l ens downward unti l l ens
hook i s cl ear of headl i ni ng.
(4) Sl i de dome l amp toward ri ght si de of vehi cl e
unti l hook on dome l amp i s cl ear of headl i ni ng (Fi g.
12).
(5) Remove dome l amp from headl i ni ng.
(6) Di sconnect wi re connector from dome l amp.
(7) Remove dome l amp from vehi cl e.
INSTALLATION
(1) Posi ti on dome l amp i n vehi cl e.
(2) Connect wi re connector to dome l amp.
(3) Posi ti on dome l amp to headl i ni ng.
(4) Posi ti on hook on dome l amp above headl i ni ng
and sl i de l amp toward l eft si de of vehi cl e unti l hook
on dome l amp i s ful l y engaged to headl i ni ng.
(5) Push upward on dome l amp unti l dome l amp i s
ti ght to headl i ni ng.
(6) Pi vot dome l amp l ens upward. Veri fy that l amp
l ens hook i s above the headl i ni ng.
(7) I nstal l l eft si de of dome l amp l ens to l amp
body.
DOME LAMP BULB
REMOVAL
dome l amp l ens and dome l amp body on l eft si de of
dome l amp.
(2) Di sengage l eft si de of dome l amp l ens from
(3) Pul l bul b from l amp socket
INSTALLATION
(1) Push bul b i nto l amp socket.
(2) Pi vot dome l amp l ens upward. Veri fy that l amp
l ens hook i s above the headl i ni ng.
(3) Engage l eft si de of dome l amp l ens to l amp
body.
FRONT DOOR COURTESY LAMP
REMOVAL
(1) I nsert a tri msti ck between courtesy l amp hous-
i ng and door tri m panel (Fi g. 14).
(2) Pry rear edge of housi ng from tri m panel .
Fig. 11 Dome Lamp Lens
Fig. 12 Dome Lamp Hook
Fig. 13 Dome Lamp Bulb
NS LAMPS 8L - 21
(3) Separate housi ng from tri m panel .
(4) Di sengage wi re connector from l amp.
(5) Separate l amp housi ng from vehi cl e.
INSTALLATION
(1) Posi ti on l amp housi ng to vehi cl e.
(2) Engage wi re connector to l amp.
(3) Sl i de tab on forward edge of housi ng behi nd
tri m panel .
(4) Snap rear edge of housi ng i nto tri m panel .
FRONT DOOR COURTESY LAMP BULB
REMOVAL
(1) Usi ng a smal l , fl at bl aded pry tool , pry rear
edge of courtesy l amp l ens from courtesy l amp (Fi g.
15).
(2) Remove l ens from l amp.
(3) Squeeze brass l amp bul b contacts together gen-
tl y.
(4) Di sengage bul b from l amp contacts (Fi g. 16).
(5) Remove bul b from l amp.
Fig. 14 Door Courtesy Lamp Housing
Fig. 15 Door Courtesy Lamp Lens
Fig. 16 Door Courtesy Lamp Bulb
8L - 22 LAMPS NS
INSTALLATION
(1) Posi ti on bul b to l amp contacts.
(2) Engage bul b to l amp contacts.
(3) I nsert l ong edge of l ens i nto l amp housi ng.
(4) Press on center of l ens to engage remai nder of
cl i ps
RAIL LAMP MODULE BULB
REMOVAL
(1) Usi ng a smal l screw dri ver, pry stati onary end
of rai l l amp l ens from rai l l amp modul e (Fi g. 17).
(2) Remove l ens tab from between rai l l amp mod-
ul e and rai l l amp swi tch.
(3) Remove l ens from l amp.
(4) Pul l bul b from l amp (Fi g. 18).
INSTALLATION
(1) Push bul b i nto bul b contacts i n rai l l amp mod-
ul e.
(2) I nsert tab on l amp l ens between rai l l amp mod-
ul e and rai l l amp swi tch.
(3) Snap l ens onto l ens pi vots on modul e.
LIFTGATE COURTESY LAMP
REMOVAL
(1) I nsert tri m sti ck between courtesy l amp and
l i ftgate tri m panel at upper i nboard corner of cour-
tesy l amp (Fi g. 19).
(2) Di sengage tabs hol di ng courtesy l amp to l i ft-
gate tri m panel (Fi g. 20).
(3) Di sconnect wi re connector from courtesy l amp.
(4) Remove l amp from vehi cl e.
INSTALLATION
(1) Posi ti on l amp to vehi cl e.
(2) Connect wi re connector to courtesy l amp.
Fig. 17 Rail Lamp Module Lens
Fig. 18 Rail Lamp Module Bulb
Fig. 19 Courtesy Lamp
Fig. 20 Courtesy Lamp Tabs
NS LAMPS 8L - 23
(3) Posi ti on courtesy l amp to l i ftgate tri m panel .
(4) Press courtesy l amp i nto tri m panel unti l tabs
engage ful l y to tri m panel .
LIFTGATE COURTESY LAMP BULB
REMOVAL
(1) Remove l i ftgate courtesy l amp.
courtesy l amp l ens and courtesy l amp body.
(3) Careful l y depress tabs hol di ng l ens to courtesy
(4) Remove l amp l ens from l amp body.
(5) Careful l y press l amp bul b contact toward oppo-
si te contact.
(6) Remove bul b from l amp body.
INSTALLATION
(1) Careful l y press l amp bul b contact toward oppo-
si te contact.
(2) Posi ti on bul b to l amp bul b contacts.
(3) Posi ti on l ong si de of l amp l ens to tabs on l amp
body.
(4) Press on center of l ens to engage tabs on oppo-
si te si de of l amp body.
(5) I nstal l l i ftgate courtesy l amp.
Fig. 21 Liftgate Courtesy Lamp Bulb
8L - 24 LAMPS NS
BULB APPLICATION
INDEX
page page
GENERAL INFORMATION
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . 25
SPECIFICATIONS
EXTERIOR LAMP BULBS . . . . . . . . . . . . . . . . . . 25
INTERIOR LAMP BULBS . . . . . . . . . . . . . . . . . . 25
GENERAL INFORMATION
INTRODUCTION
The fol l owi ng Bul b Appl i cati on Tabl es l i st the l amp
ti tl e on the l eft si de of the col umn and trade number
or part number on the ri ght.
CAUTION: Do not use bulbs that have a higher
candle power than the bulb listed in the Bulb Appli-
cation Table. Damage to lamp can result.
Do not touch halogen bulbs with fingers or other
possibly oily surfaces. Bulb life will be reduced.
I f a hal ogen bul b i s contami nated wi th oi l , cl ean
bul b wi th denatured al cohol or ammoni a based sol -
vent.
SPECIFICATIONS
EXTERIOR LAMP BULBS
LAMP BULB
Back-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3057
CHMSL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .921
Fog Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H3
Fog Lamp T&C . . . . . . . . . . . . . . . . . . . . . . . .9040
Headl amp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9007
Headl amp hi gh beam T&C . . . . . . . . . . . . . . .9005
Headl amp l ow beam T&C . . . . . . . . . . . .9005 SLL
Li cense Pl ate . . . . . . . . . . . . . . . . . . . . . . . . . . . .168
Parki ng/Turn Si gnal /Front Si de Marker . . . .3157NA
Parki ng/Turn Si gnal T&C . . . . . . . . . . . .4157NAK
Tai l , Stop, Turn Si gnal and Si de Marker . . . . . .3057
Front Si de Marker . . . . . . . . . . . . . . . . . . . . . .194NA
INTERIOR LAMP BULBS
LAMP BULB
ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PC194
Ai r Bag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PC194
Al arm Set (Securi ty) . . . . . . . . . . . . . . . . . . . .PC194
Brake Warni ng. . . . . . . . . . . . . . . . . . . . . . . . .PC194
Center/Rear Readi ng Lamps . . . . . . . . . . . . . . . . .578
Center/Rear Dome Lamps. . . . . . . . . . . . . . . . . . .579
Check Engi ne I nd. . . . . . . . . . . . . . . . . . . . . . .PC194
Front Door Courtesy . . . . . . . . . . . . . . . . . . . . . . .567
Door Ajar I nd. . . . . . . . . . . . . . . . . . . . . . . . . .PC194
Front Header Readi ng Lamp . . . . . . . . . . . . . . . .567
Gl ove Box Lamp . . . . . . . . . . . . . . . . . . . . . . . . . .194
Hi gh Beam I nd. . . . . . . . . . . . . . . . . . . . . . . . .PC194
I nstrument Cl uster . . . . . . . . . . . . . . . . . . . . .PC194
I P Bi n/Ash Tray . . . . . . . . . . . . . . . . . . . . . . . . . .161
Li ftgate Fl ood Lamps . . . . . . . . . . . . . . . . . . . . . .567
Li ftgate Ajar I nd. . . . . . . . . . . . . . . . . . . . . . . . .PC74
Low Fuel I nd. . . . . . . . . . . . . . . . . . . . . . . . . .PC194
Oi l Pressure I nd. . . . . . . . . . . . . . . . . . . . . . . .PC194
O/H Consol e Readi ng Lamps . . . . . . . . . . . . . . . .579
Seat Bel t I nd. . . . . . . . . . . . . . . . . . . . . . . . . . .PC74
Engi ne Temp I nd. . . . . . . . . . . . . . . . . . . . . . .PC194
Turn Si gnal . . . . . . . . . . . . . . . . . . . . . . . . . . .PC194
Engi ne Compartment Lamps . . . . . . . . . . . . . . . .579
Vi sor Vani ty Lamp . . . . . . . . . . . . . . . . . . . .6501966
Low Washer Fl ui d . . . . . . . . . . . . . . . . . . . . . . .PC74
Low Vol ts Warni ng. . . . . . . . . . . . . . . . . . . . . . .PC74
Crui se I ndi cator . . . . . . . . . . . . . . . . . . . . . . . .PC194
NS LAMPS 8L - 25
LAMPS
CONTENTS
page page
BULB APPLICATION . . . . . . . . . . . . . . . . . . . . . 17
HEADLAMP ALIGNMENT . . . . . . . . . . . . . . . . . . 5
LAMP BULB SERVICE . . . . . . . . . . . . . . . . . . . . 8
LAMP DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . 1
LAMP SERVICE . . . . . . . . . . . . . . . . . . . . . . . . 13
LAMP DIAGNOSIS
INDEX
page page
GENERAL INFORMATION
HEADLAMP LEVELING MOTOR . . . . . . . . . . . . . 2
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . 1
SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . 1
DIAGNOSTIC PROCEDURES . . . . . . . . . . . . . . 2
GENERAL INFORMATION
INTRODUCTION
GS vehi cl es use l i ghti ng on the i nteri or and exte-
ri or of the vehi cl e for i l l umi nati ng and i ndi cati ng
purposes. Li ghti ng ci rcui ts are protected by fuses.
Li ghti ng ci rcui ts requi re an overl oad protected power
source, on/off devi ce, l amps and body ground to oper-
ate properl y. Pl asti c l amps requi re a wi re i n the har-
ness to suppl y body ground to the l amp socket.
Repl ace sockets and bul bs that are corroded.
Some of the i nteri or and exteri or l i ghti ng functi ons
are governed by the body control l er. The headl amp,
dome, and the door ajar swi tches provi de si gnal s to
the body control l er. The body control l er i n turn acti -
vates rel ay(s) i n order to provi de ei ther a ground or
feed l i ne to the appropri ate l amp(s).
Wi re connectors can make i ntermi ttent contact or
become corroded. Before coupl i ng wi re connectors,
i nspect the termi nal s i nsi de the connector. Mal e ter-
mi nal s shoul d not be bent or di sengaged from the
i nsul ator. Femal e termi nal s shoul d not be sprung
open or di sengaged from the i nsul ator. Bent and
sprung termi nal s can be repai red usi ng needl e nose
pl i ers and pi ck tool . Corroded termi nal s appear
chal ky or green. Corroded termi nal s shoul d be
repl aced to avoi d recurrence of the probl em symp-
toms.
Begi n el ectri cal system fai l ure di agnosi s by testi ng
rel ated fuses i n the fuse bl ock and power di stri buti on
center. Veri fy that bul bs are i n good condi ti on and
test conti nui ty of the ci rcui t ground. Refer to Group
8W, Wi ri ng Di agrams, for component l ocati on and ci r-
SAFETY PRECAUTIONS
Do not use bulbs with higher candle power than
indicated in the Bulb Application table at the end of
this group. Damage to lamp and/or Daytime Run-
ning Lamp Module can result.
Do not use fuses, circuit breakers or relays hav-
ing greater amperage value than indicated on the
fuse panel or in the Owners Manual.
fasteners or captured edges are not hol di ng the com-
ponent i n pl ace.
NS/GS LAMPS 8L - 1
HEADLAMP LEVELING MOTOR
Thi s vehi cl e i s equi pped wi th a remote headl amp
l evel i ng system. Thi s system al l ows the dri ver to
adjust the verti cal headl amp ai m from the i nteri or of
the vehi cl e to compensate for passenger or cargo
l oad. A headl amp l evel i ng swi tch i s l ocated i n the
i nstrument panel and control s the headl amp l evel i ng
motor found on the back of the headl amp modul e.
When a vehi cl e experi ences probl ems wi th the head-
l amp system, veri fy the condi ti on of the battery connec-
ti ons, chargi ng system, headl amp bul bs, wi re
connectors, rel ay, hi gh beam di mmer swi tch and head-
l amp swi tch. Refer to Group 8W, Wi ri ng Di agrams, for
component l ocati ons and ci rcui t i nformati on.
HEADLAMP DIAGNOSIS
HEADLAMPS ARE DIM
WITH ENGINE IDLING OR
IGNITION TURNED OFF
1. Loose or corroded battery cables. 1. Clean and secure battery cable clamps
and posts.
2. Loose or worn alternator drive
belt.
2. Adjust or replace alternator drive belt.
3. Charging system output too low. 3. Test and repair charging system. Refer
to Group 8A.
4. Battery has insufficient charge. 4. Test battery state-of -charge. Refer to
Group 8A.
5. Battery is sulfated or shorted. 5. Load test battery. Refer to Group 8A.
HEADLAMP BULBS BURN
OUT FREQUENTLY
1. Charging system output too high. 1. Test and repair charging system. Refer
to Group 8A.
splices in circuit.
HEADLAMPS ARE DIM
WITH ENGINE RUNNING
ABOVE IDLE
1. Charging system output too low. 1. Test and repair charging system. Refer
to Group 8A.
3. High resistance in headlamp
circuit.
3. Test amperage draw of headlamp circuit.
HEADLAMPS FLASH
RANDOMLY
locations, refer to Group 8W.
2. High resistance in headlamp
circuit.
2. Test amperage draw of headlamp circuit.
splices in circuit.
HEADLAMPS DO NOT
ILLUMINATE
1. No voltage to headlamps. 1. Repair open headlamp circuit. Refer to
Group 8W.
2. No Z1-ground at headlamps. 2. Repair circuit ground. Refer to Group
8W.
3. Faulty headlamp switch. 3. Replace headlamp switch.
4. Faulty headlamp dimmer
(multi-function) switch.
4. Replace multi-function switch.
splice in headlamp circuit.
5. Repair connector terminal or wire splice.
7. Body controller malfunction. 7. Refer to appropriate body controller
diagnostics.
8L - 2 LAMPS NS/GS
FOG LAMP DIAGNOSIS
ENGINE IDLING OR IGNITION
TURNED OFF.
1. Loose or corroded battery cables. 1. Clean and secure battery cable
clamps and posts.
2. Loose or worn alternator drive
belt.
2. Adjust or replace alternator drive
belt.
Refer to Group 8A,
4. Battery has insufficient charge. 4. Test battery state-of -charge.
Refer to Group 8A.
5. Battery is sulfated or shorted. 5. Load test battery. Refer to Group
8A.
8W.
FOG LAMP BULBS BURN OUT
FREQUENTLY
1. Charging system output too high. 1. Test and repair charging system.
Refer to Group 8A.
splices in circuit.
ENGINE RUNNING ABOVE IDLE
Refer to Group 8A.
8W.
circuit.
circuit.
FOG LAMPS FLASH RANDOMLY 1. Poor lighting circuit Z1-ground. 1. Test for voltage drop across
8W.
circuit.
circuit.
splices in circuit.
FOG LAMPS DO NOT
ILLUMINATE
1. Blown fuse for fog lamp. 1. Replace fuse. Refer to Group 8W.
2. No Z1-ground at fog lamps. 2. Repair circuit ground. Refer to
Group 8W.
splice in fog lamp circuit.
4. Repair connector terminal or wire
splice.
NS/GS LAMPS 8L - 3
HEADLAMP LEVELING MOTOR DIAGNOSIS
ONE MOTOR DOES NOT
OPERATE
1. Poor connection at motor. 1. Secure connector on motor.
2. No voltage at motor. 2. Repair circuit. Refer to Group 8W,
Wiring.
3. Defective motor. 3. Replace motor.
BOTH MOTORS DO NOT
OPERATE
1. No voltage at headlamp leveling
switch.
1. Repair circuit or replace fuse.
Refer to Group 8W, Wiring.
2. No voltage at both motors. 2. Repair circuit or replace fuse.
Refer to Group 8W, Wiring.
3. Poor connection at motors. 3. Secure connectors on motors.
4. Both motors defective. 4. Replace motors.
8L - 4 LAMPS NS/GS
HEADLAMP ALIGNMENT
INDEX
page page
SERVICE PROCEDURES
HEADLAMP ALIGNMENT PREPARATION . . . . . . 5
ADJUSTMENTS
ALIGNMENT SCREEN . . . . . . . . . . . . . . . . . . 5
SERVICE PROCEDURES
HEADLAMP ALIGNMENT PREPARATION
(1) Veri fy headl amp di mmer swi tch and hi gh beam
i ndi cator operati on.
(2) Veri fy that the headl amp l evel i ng swi tch i s i n
the 0 posi ti on.
(3) I nspect and correct damaged or defecti ve com-
ponents that coul d i nterfere wi th proper headl amp
al i gnment.
(4) Veri fy proper ti re i nfl ati on.
(5) Cl ean headl amp l enses.
(6) Veri fy that l uggage area i s l oaded as the vehi -
cl e i s routi nel y used.
(7) Fuel tank shoul d be FULL. Add 2.94 kg (6.5
l bs.) of wei ght over the fuel tank for each esti mated
gal l on of mi ssi ng fuel .
ADJ USTMENTS
ALIGNMENT SCREEN
ALIGNMENT SCREEN PREPARATION
(1) Posi ti on vehi cl e on a l evel surface perpendi cu-
l ar to a fl at wal l 10 meters (32.8 ft.) away from front
of headl amp l ens (Fi g. 1).
(2) Pl ace 75 kg i n the dri vers seat to si mul ate the
ri de hei ght of the vehi cl e when dri ven.
(3) I f necessary, tape a l i ne on the fl oor 10 meters
(32.8 ft) away from and paral l el to the wal l .
(4) From the fl oor up 1.27 meters (5 ft), tape a l i ne
on the wal l at the centerl i ne of the vehi cl e. Si ght
al ong the centerl i ne of the vehi cl e (from rear of vehi -
cl e forward) to veri fy accuracy of the l i ne pl acement.
NS/GS LAMPS 8L - 5
(5) Rock vehi cl e si de-to-si de three ti mes and al l ow
suspensi on to stabi l i ze.
(6) Jounce front suspensi on three ti mes by pushi ng
downward on front bumper and rel easi ng.
(7) Measure the di stance from the center of head-
l amp l ens to the fl oor. Transfer measurement to the
al i gnment screen (wi th tape). Use thi s l i ne for
up/down adjustment reference.
(8) Pl ace a tape l i ne 130 mm bel ow and paral l el to
the center of headl amp l i ne.
(9) Measure di stance from the centerl i ne of the
vehi cl e to the center of each headl amp bei ng al i gned.
Transfer measurements to screen (wi th tape) to each
si de of vehi cl e centerl i ne. Use these l i nes for l eft/
ri ght adjustment reference.
HEADLAMP ADJ USTMENT
A properl y ai med l ow beam headl amp wi l l project a
hi gh i ntensi ty l i ght pattern on the screen wi th the
hori zontal cut-off l i ne al i gned wi th the tape l i ne 130
mm (5.12 i n.) bel ow the headl amp centerl i ne (Fi g. 1).
The i ntersecti on of the hori zontal and 15 degree cut-
off l i nes i n the projected pattern shoul d al i gn to the
i ntersecti on of the headl amp centerl i ne verti cal tape
l i ne and the tape l i ne 130 mm (5.12 i n.) bel ow the
headl amp hori zontal centerl i ne. The hi gh beams on a
vehi cl e wi th aero headl amps cannot be al i gned. The
Fig. 1 Headlamp Alignment Screen
8L - 6 LAMPS NS/GS
To adjust headl amp al i gnment, rotate al i gnment
pattern (Fi g. 2).
FOG LAMP ALIGNMENT
Prepare an al i gnment screen. Refer to the Al i gn-
ment Screen Preparati on paragraph i n thi s secti on. A
properl y al i gned fog l amp wi l l project a pattern on
the al i gnment screen 200 mm (8 i n.) bel ow the fog
l amp centerl i ne and strai ght ahead (Fi g. 3). To
i mprove vi sual i nterpretati on of the fog l amp pattern
on the al i gnment screen, di sabl e the headl amps by
di sengagi ng the wi re connectors from the headl amp
bul bs.
Fig. 3 Fog Lamp Alignment
Fig. 2 Headlamp AdjustersLeft Side Shown
NS/GS LAMPS 8L - 7
LAMP BULB SERVICE
INDEX
page page
(CHMSL) BULB . . . . . . . . . . . . . . . . . . . . . . . 12
CITYLIGHT LAMP BULB . . . . . . . . . . . . . . . . . . 9
FOG LAMP BULB . . . . . . . . . . . . . . . . . . . . . . . . 9
FRONT TURN SIGNAL LAMP BULB . . . . . . . . . . 8
HEADLAMP BULB . . . . . . . . . . . . . . . . . . . . . . . 8
LICENSE PLATE LAMP BULB . . . . . . . . . . . . . 12
SIDE REPEATER LAMP BULB . . . . . . . . . . . . . 10
TAIL LAMP BULB . . . . . . . . . . . . . . . . . . . . . . . 10
HEADLAMP BULB
REMOVAL
(2) Remove headl amp modul e from vehi cl e.
(3) Remove rubber seal boot (Fi g. 1).
(4) Di sengage retai ni ng spri ng cl i p from headl amp
(Fi g. 2).
(5) Pi vot spri ng cl i p from headl amp bul b removal
path.
(6) Pul l headl amp bul b from back of headl amp
(Fi g. 3).
INSTALLATION
with fingers of other possibly oily surface. Reduced
(1) I nsert headl amp bul b to headl amp.
(2) Pi vot spri ng cl i p over headl amp bul b.
(3) Engage retai ni ng spri ng cl i p to headl amp.
(4) I nstal l rubber seal boot.
(5) Engage wi re connector to headl amp bul b base.
(6) I nstal l headl amp modul e i nto vehi cl e
FRONT TURN SIGNAL LAMP BULB
REMOVAL
(1) Remove headl amp modul e from vehi cl e
Fig. 1 Rubber Boot Seal
Fig. 2 Headlamp Bulb Spring Clip
Fig. 3 Headlamp Bulb
8L - 8 LAMPS NS/GS
(2) Rotate front turn si gnal l amp socket one quar-
ter turn countercl ockwi se.
(3) Pul l socket from back of l amp.
INSTALLATION
i nsert bul b i nto socket.
(2) I nsert socket i nto back of headl amp.
(3) Rotate front turn si gnal socket cl ockwi se one
quarter turn.
(4) I nstal l headl amp modul e i nto vehi cl e.
(5) Veri fy l amp operati on.
CITYLIGHT LAMP BULB
REMOVAL
(1) Remove the headl amp modul e.
(2) Pul l ci tyl i ght l amp from rubber bushi ng i n
headl amp housi ng (Fi g. 5).
INSTALLATION
(1) Posi ti on ci tyl i ght l amp bul b to l amp socket.
(3) Push ci tyl i ght l amp i nto bushi ng i n headl amp
housi ng.
(4) I nstal l headl amp modul e to vehi cl e.
FOG LAMP BULB
REMOVAL
(2) Remove rear cover from fog l amp.
(3) Di sengage wi re cl i p hol di ng bul b i n fog l amp
(Fi g. 7).
(4) Hi nge wi re retai ner cl i p out of bul b removal
path.
(5) Pul l bul b from l amp.
(6) Di sengage wi re connector from fog l amp wi re
harness.
Fig. 4 Front Turn Signal Lamp Bulb
Fig. 5 Citylight Lamp Socket
Fig. 6 Citylight Lamp Bulb
Fig. 7 Fog Lamp Bulb
NS/GS LAMPS 8L - 9
INSTALLATION
will result.
(1) Engage wi re connector i nto fog l amp wi re har-
ness.
(2) I nsert bul b i nto l amp so i ndex notches on bul b
engage wi th bosses i n l amp (Fi g. 7).
(3) Hi nge wi re retai ner cl i p over bul b base.
(4) Engage wi re cl i p to hol d bul b i nto l amp.
(5) I nstal l rear cover on fog l amp.
(6) I nstal l fog l amp on vehi cl e.
SIDE REPEATER LAMP BULB
REMOVAL
(1) Push si de repeater l amp to one si de and
rel ease retai ni ng tab (Fi g. 8).
(2) Pul l si de repeater l amp out and di sengage bul b
socket from l amp (Fi g. 9).
(3) Rotate and pul l bul b from socket.
INSTALLATION
(1) Push and twi st bul b i nto socket.
(2) Push si de repeater l amp socket i nto si de
repeater l amp.
(3) Posi ti on si de repeater l amp to hol e i n fender.
(4) Push si de repeater l amp to one si de and seat
retai ni ng tab i nto fender.
TAIL LAMP BULB
The tai l l amp houses the tai l /stop l amp, rear turn
si gnal l amp, back-up l amp, and rear fog l amp bul bs.
Fig. 8 Side Repeater Lamp
Fig. 9 Side Repeater Lamp Bulb
8L - 10 LAMPS NS/GS
REMOVAL
(2) Remove screws hol di ng tai l l amp to rear door
openi ng trough (Fi g. 10).
(3) Separate i nner end of l amp from quarter panel .
(5) Separate l amp from quarter panel .
(6) Remove screws hol di ng bul b hol der to l amp
(7) Separate bul b hol der from l amp housi ng.
(8) Retri eve the rubber washers that seal the bul b
hol der to the l amp housi ng at the bul b hol der screw
l ocati ons.
(9) Pul l bul b from bul b hol der socket (Fi g. 12).
INSTALLATION
(1) Al i gn key on bul b base to groove i n bul b hol der
socket and i nsert bul b i nto socket (Fi g. 12).
(2) Posi ti on bul b hol der to l amp housi ng.
(3) Veri fy that the rubber washers are properl y
posi ti oned between the bul b hol der and l amp housi ng
at the screw l ocati ons.
(4) I nstal l screws to hol d bul b hol der to l amp hous-
i ng.
(5) Posi ti on l amp to quarter panel .
ter panel openi ng.
(7) I nstal l screws to hol d l amp to rear door open-
i ng trough.
Fig. 10 Tail Lamp
Fig. 11 Tail Lamp Bulb Holder
Fig. 12 Pull Bulb From Bulb Holder
NS/GS LAMPS 8L - 11
LICENSE PLATE LAMP BULB
REMOVAL
(1) Press one retai ni ng tab on l i cense pl ate l amp
housi ng toward center of l ens (Fi g. 13).
(2) Separate l amp l ens from l amp housi ng.
(3) Pul l l amp bul b from socket.
INSTALLATION
(1) Al i gn l i cense pl ate l amp bul b to l amp socket.
(3) Posi ti on l amp l ens to l amp housi ng.
(4) Snap l amp l ens onto tabs on l amp housi ng.
BULB
REMOVAL
(2) Di sengage cl i ps hol di ng CHMSL cover to l i ft-
gate tri m panel (Fi g. 14).
(3) Separate CHMSL cover from l i ftgate tri m
panel .
(4) Depress pl asti c tab hol di ng bul b hol der to l amp
(6) Pul l bul b or i f equi pped bul bs from l amp socket
(Fi g. 16).
INSTALLATION
(1) Al i gn bul b to bul b hol der socket.
(2) Push bul b i nto bul b hol der socket.
(3) Posi ti on bul b hol der to CHMSL housi ng.
(4) Snap bul b hol der i nto CHMSL housi ng.
(5) Posi ti on CHMSL cover to l i ftgate tri m panel .
(6) Engage cl i ps to hol d CHMSL cover to l i ftgate
tri m panel .
Fig. 13 License Plate Lamp Lens
Fig. 14 CHMSL Cover
Fig. 15 CHMSL Bulb Holder
Fig. 16 CHMSL Bulb
8L - 12 LAMPS NS/GS
LAMP SERVICE
INDEX
page page
GENERAL INFORMATION
HEADLAMP DIMMER SWITCH . . . . . . . . . . . . . 13
HEADLAMP SWITCH . . . . . . . . . . . . . . . . . . . . 13
(CHMSL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
FOG LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
HEADLAMP LEVELING MOTOR . . . . . . . . . . . . 14
HEADLAMP MODULE . . . . . . . . . . . . . . . . . . . 13
LICENSE PLATE LAMP . . . . . . . . . . . . . . . . . . 15
SIDE REPEATER LAMP . . . . . . . . . . . . . . . . . . 14
TAIL LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
GENERAL INFORMATION
HEADLAMP SWITCH
Servi ce procedures for the headl amp swi tch can be
found i n Group 8E, I nstrument Panel and Gauges.
More i nformati on can be found i n Group 8W, Wi ri ng
Di agrams.
HEADLAMP DIMMER SWITCH
The headl amp di mmer swi tch i s i ncorporated i nto
the mul ti -functi on (turn si gnal ) swi tch. Proper proce-
dures can be found i n Group 8J, Turn Si gnal and
Fl ashers. More i nformati on can be found i n Group
HEADLAMP MODULE
REMOVAL
(2) Remove bol t hol di ng headl amp modul e to radi -
ator cl osure panel (Fi g. 1).
(3) From behi nd the radi ator cl osure panel , remove
the nuts hol di ng the headl amp modul e to the radi a-
(4) Separate headl amp modul e from radi ator cl o-
sure panel .
(5) Di sengage wi re connector from headl amp bul b.
(6) Di sengage wi re connector from headl amp l evel -
i ng motor.
(7) Di sengage wi re connector for front turn si gnal
and ci tyl i ght l amps.
(8) Separate headl amp modul e from vehi cl e.
INSTALLATION
(1) Posi ti on headl amp modul e to vehi cl e.
(2) Engage wi re connector for front turn si gnal and
ci tyl i ght l amps.
(3) Engage wi re connector to headl amp l evel i ng
motor.
(4) Engage wi re connector to headl amp bul b.
(5) Posi ti on headl amp modul e to radi ator cl osure
panel .
(6) Press headl amp modul e rearward unti l modul e
i s ful l y seated onto mounti ng studs.
(7) I nstal l nuts to hol d headl amp modul e to radi a-
Fig. 1 Headlamp Module
NS/GS LAMPS 8L - 13
HEADLAMP LEVELING MOTOR
REMOVAL
(1) Remove headl amp modul e from vehi cl e.
(2) Rotate l evel i ng motor one quarter turn counter-
cl ockwi se.
(3) Pul l l evel i ng motor from headl amp housi ng
(Fi g. 2).
NOTE: The headlamp leveling motor arm is
snapped into the lens reflector mechanism very
securely. Use a firm, steady pull to disengage motor
arm from reflector mechanism.
(4) Separate l evel i ng motor from headl amp hous-
i ng.
INSTALLATION
(1) Posi ti on headl amp l evel i ng motor to headl amp
housi ng.
(2) I nsert l evel i ng motor arm i nto hol e i n backsi de
of headl amp housi ng.
(3) Push headl amp bul b toward top of headl amp
housi ng (Fi g. 3).
(4) Push l evel i ng motor fi rml y i nto headl amp
housi ng unti l l evel i ng motor arm i s ful l y seated i nto
refl ector mechani sm.
(5) Rotate l evel i ng motor one quarter turn cl ock-
wi se.
(6) I nstal l headl amp modul e to vehi cl e.
FOG LAMP
REMOVAL
(1) Remove screws hol di ng fog l amp to front
bumper fasci a (Fi g. 4).
(2) Separate fog l amp from fasci a.
(3) Di sengage wi re connector from body wi re har-
ness.
(4) Separate fog l amp from vehi cl e.
INSTALLATION
(2) Engage wi re connector to body wi re harness.
(3) I nsert fog l amp i nto bumper fasci a.
(4) I nstal l screws to hol d fog l amp to front bumper
fasci a.
SIDE REPEATER LAMP
REMOVAL
(1) Push si de repeater l amp to one si de and
rel ease retai ni ng tab (Fi g. 5).
(2) Pul l si de repeater l amp out and di sengage bul b
socket from l amp (Fi g. 6).
(3) Separate si de repeater l amp from vehi cl e.
INSTALLATION
(1) Push si de repeater l amp socket i nto si de
repeater l amp.
(2) Posi ti on si de repeater l amp to hol e i n fender.
(3) Push si de repeater l amp to one si de and seat
retai ni ng tab i nto fender.
Fig. 2 Headlamp Leveling Motor
Fig. 3 Headlamp Leveling Motor Installation
Fig. 4 Fog Lamp
8L - 14 LAMPS NS/GS
TAIL LAMP
The tai l l amp houses the tai l /stop l amp, rear turn
si gnal l amp, back-up l amp, and rear fog l amp bul bs.
REMOVAL
(2) Remove screws hol di ng tai l l amp to rear door
openi ng trough.
(3) Separate i nner end of l amp from quarter panel .
(5) Separate l amp from quarter panel (Fi g. 7).
(6) Di sengage posi ti ve l ock on wi re connector (Fi g.
8).
(7) Depress l ock tab on the si de of the body har-
ness connector.
(8) Di sengage wi re connector from bul b hol der.
(9) Separate tai l l amp from vehi cl e.
INSTALLATION
(1) Pl ace tai l l amp i n posi ti on on vehi cl e.
(2) Engage wi re connector i nto bul b hol der.
(3) Engage posi ti ve l ock on wi re connector.
(4) Pl ace l amp i n posi ti on i n posi ti on on quarter
panel .
ter panel openi ng.
(6) Posi ti on i nner end of l amp i nto quarter panel .
(7) I nstal l screws to hol d tai l l amp to rear door
openi ng trough.
LICENSE PLATE LAMP
REMOVAL
(2) Remove l i ftgate tri m panel . Refer to Group 23,
Body, for proper procedures.
access to wi re connector.
(4) Di sengage wi re connector from l i ftgate wi re
harness.
(5) Remove screws hol di ng l i cense pl ate l amp bar
to l i ftgate.
Fig. 5 Side Repeater Lamp
Fig. 6 Side Repeater Lamp Socket
Fig. 7 Tail Lamp
Fig. 8 Tail Lamp Connector
NS/GS LAMPS 8L - 15
(6) Separate l i cense pl ate l amp bar from l i ftgate
(Fi g. 9).
(7) Separate l i cense pl ate l amp bar grommet from
vehi cl e.
INSTALLATION
(1) Route wi re connector through hol e i n l i ftgate.
(2) I nstal l grommet to wi ri ng harness hol e i n l i ft-
gate.
(3) Pl ace l i cense pl ate l amp bar i n posi ti on on l i ft-
gate.
(4) I nstal l screws to hol d l i cense pl ate l amp bar to
l i ftgate.
(5) Engage wi re connector i nto l i ftgate wi re har-
ness.
REMOVAL
(2) Di sengage cl i p hol di ng CHMSL access cover to
l i ftgate.
(3) Separate cover from l i ftgate.
(4) Depress pl asti c tab hol di ng bul b hol der to l amp
(6) Remove screws hol di ng CHMSL to l i ftgate.
(7) Separate CHMSL from vehi cl e.
INSTALLATION
(1) Pl ace CHMSL i n posi ti on on vehi cl e.
(2) I nstal l screws to hol d CHMSL to l i ftgate.
(3) Posi ti on bul b hol der to CHMSL housi ng.
(4) Snap bul b hol der i nto CHMSL housi ng.
(5) Pl ace CHMSL access cover i n posi ti on on l i ft-
gate.
(6) Engage cl i p to hol d access cover to l i ftgate.
Fig. 9 License Plate Lamp
Fig. 10 CHMSL Bulb Holder
8L - 16 LAMPS NS/GS
BULB APPLICATION
INDEX
page page
GENERAL INFORMATION
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . 17
HEADLAMP CLEANING . . . . . . . . . . . . . . . . . . 17
SPECIFICATIONS
EXTERIOR LAMP BULBS . . . . . . . . . . . . . . . . . 17
INTERIOR LAMP BULBS . . . . . . . . . . . . . . . . . 17
GENERAL INFORMATION
INTRODUCTION
The fol l owi ng Bul b Appl i cati on Tabl es l i st the l amp
ti tl e on the l eft si de of the col umn and trade number
or part number on the ri ght.
CAUTION: Do not use bulbs that have a higher
candle power than the bulb listed in the Bulb Appli-
cation Table. Damage to lamp can result.
Do not touch halogen bulbs with fingers or other
possibly oily surfaces. Bulb life will be reduced.
I f a hal ogen bul b i s contami nated wi th oi l , cl ean
bul b wi th denatured al cohol or ammoni a based sol -
vent.
HEADLAMP CLEANING
Thi s vehi cl e i s equi pped wi th pl asti c headl i ghts
that are l i ghter and l ess suscepti bl e to stone break-
age than gl ass headl i ghts.
Thi s pl asti c i s not as scratch resi stant as gl ass and
therefore a di fferent l ens cl eani ng procedures must
be fol l owed.
To mi ni mi ze the possi bi l i ty of scratchi ng the l enses
and reduci ng l i ght output, avoi d wi pi ng wi th a dry
cl oth. To remove road di rt, wash wi th a mi l d soap
sol uti on fol l owed by ri nsi ng wi th water.
Do not use abrasi ve cl eani ng components, sol vents,
steel wool or other aggressi ve materi al to cl ean the
l enses.
SPECIFICATIONS
EXTERIOR LAMP BULBS
LAMP BULB
Back-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P21W
CHMSL (Non-Sol ar Ti nt) . . . . . . . . . . . . . . . . P21W
CHMSL (Sol ar Ti nt) . . . . . . . . . . . . . . . . . . . . R10W
LAMP BULB
Fog Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3
Headl amp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H4
Li cense Pl ate . . . . . . . . . . . . . . . . . . . . . . . . . . C5W
Front Turn Si gnal . . . . . . . . . . . . . . . . . . . . PY21W
Ci tyl i ght . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4W
Front Si de Repeater . . . . . . . . . . . . . . . . . . . . . T4W
Tai l , Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . P21/5W
Rear Turn Si gnal . . . . . . . . . . . . . . . . . . . . . . P21W
Rear Fog Lamp . . . . . . . . . . . . . . . . . . . . . . . . P21W
INTERIOR LAMP BULBS
LAMP BULB
ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PC194
Ai r Bag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PC194
Al arm Set (Securi ty/I mmobi l zer) . . . . . . . . . . PC194
Brake Warni ng . . . . . . . . . . . . . . . . . . . . . . . PC194
Center/Rear Readi ng Lamps . . . . . . . . . . . . . . . 578
Center/Rear Dome Lamps . . . . . . . . . . . . . . . . . 579
Crui se I ndi cator . . . . . . . . . . . . . . . . . . . . . . . PC194
Door Ajar I ndi cator . . . . . . . . . . . . . . . . . . . . PC194
Engi ne Compartment Lamps . . . . . . . . . . . . . . . 579
Engi ne Temp I ndi cator . . . . . . . . . . . . . . . . . PC194
Front Door Courtesy . . . . . . . . . . . . . . . . . . . . . . 567
Gl ove Box Lamp . . . . . . . . . . . . . . . . . . . . . . . . . 194
Gl ow Pl ug I ndi cator (Di esel Engi ne Onl y) . . . PC194
Hi gh Beam I ndi cator . . . . . . . . . . . . . . . . . . . PC194
I nstrument Cl uster . . . . . . . . . . . . . . . . . . . . PC194
I P/Ash Tray (Left Hand Dri ve Onl y) . . . . . . . . . 161
Li ftgate Fl ood Lamps . . . . . . . . . . . . . . . . . . . . . 567
Li ftgate Ajar I ndi cator . . . . . . . . . . . . . . . . . . . PC74
Low Cool ant Level (Di esel Engi ne Onl y) . . . . . PC74
Low Fuel I ndi cator . . . . . . . . . . . . . . . . . . . . PC194
Low Vol ts Warni ng . . . . . . . . . . . . . . . . . . . . . PC74
Low Washer Fl ui d . . . . . . . . . . . . . . . . . . . . . . PC74
Oi l Pressure I ndi cator . . . . . . . . . . . . . . . . . . PC194
O/H Consol e Readi ng Lamps . . . . . . . . . . . . . . . 579
Seat Bel t I ndi cator (Except Di esel ) . . . . . . . . . PC74
Servi ce Engi ne Soon . . . . . . . . . . . . . . . . . . . PC194
Turn Si gnal . . . . . . . . . . . . . . . . . . . . . . . . . . PC194
Vi sor Vani ty Lamp . . . . . . . . . . . . . . . . . . . 6501966
NS/GS LAMPS 8L - 17
RESTRAINT SYSTEM
CONTENTS
page page
GENERAL INFORMATION
WARNINGS AND PRECAUTIONS . . . . . . . . . . . . 1
AIRBAG CONTROL MODULE (ACM) . . . . . . . . . 1
CLOCKSPRING . . . . . . . . . . . . . . . . . . . . . . . . . . 2
DRIVER AND PASSENGER
AIRBAG MODULES . . . . . . . . . . . . . . . . . . . . . 2
AIRBAG SYSTEM TEST . . . . . . . . . . . . . . . . . . . 2
SERVICE PROCEDURES
CLEANUP PROCEDURE . . . . . . . . . . . . . . . . . . . 3
HANDLING AIRBAG MODULE . . . . . . . . . . . . . . 3
AIRBAG CONTROL MODULE . . . . . . . . . . . . . . . 3
CLOCKSPRING . . . . . . . . . . . . . . . . . . . . . . . . . . 5
DRIVER AIRBAG MODULE . . . . . . . . . . . . . . . . . 5
PASSENGER AIRBAG . . . . . . . . . . . . . . . . . . . . . 6
ADJUSTMENTS
CLOCKSPRING CENTERING PROCEDURE . . . . . 7
GENERAL INFORMATION
WARNINGS AND PRECAUTIONS
WARNING: THIS SYSTEM IS A SENSITIVE, COM-
PLEX ELECTROMECHANICAL UNIT. DISCONNECT
AND ISOLATE THE BATTERY NEGATIVE CABLE
BEFORE BEGINNING AIRBAG SYSTEM COMPO-
NENT REMOVAL OR INSTALLATION PROCEDURES.
THIS WILL DISABLE THE AIRBAG SYSTEM. FAIL-
URE TO DISCONNECT THE BATTERY COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
ALLOW SYSTEM CAPACITOR TO DISCHARGE
FOR TWO MINUTES BEFORE REMOVING AIRBAG
COMPONENTS.
DO NOT PLACE AN INTACT UNDEPLOYED AIR-
BAG FACE DOWN ON A SOLID SURFACE, THE AIR-
BAG WILL PROPEL INTO THE AIR IF
ACCIDENTALLY DEPLOYED AND COULD RESULT
IN PERSONAL INJURY. WHEN CARRYING OR HAN-
DLING AN UNDEPLOYED AIRBAG MODULE, THE
TRIM SIDE OF THE AIRBAG SHOULD BE POINTING
AWAY FROM THE BODY TO MINIMIZE POSSIBILITY
OF INJURY IF ACCIDENTAL DEPLOYMENT
OCCURS.
REPLACE AIRBAG SYSTEM COMPONENTS WITH
MOPAR REPLACEMENT PARTS. SUBSTITUTE
PARTS MAY APPEAR INTERCHANGEABLE, BUT
INTERNAL DIFFERENCES MAY RESULT IN INFE-
RIOR OCCUPANT PROTECTION.
WEAR SAFETY GLASSES, RUBBER GLOVES,
AND LONG SLEEVED CLOTHING WHEN CLEANING
POWDER RESIDUE FROM VEHICLE AFTER AIRBAG
DEPLOYMENT. SODIUM HYDROXIDE POWDER
RESIDUE EMITTED FROM A DEPLOYED AIRBAG
CAN CAUSE SKIN IRRITATION. FLUSH AFFECTED
AREA WITH COOL WATER IF IRRITATION IS EXPE-
RIENCED. IF NASAL OR THROAT IRRITATION IS
EXPERIENCED, EXIT THE VEHICLE FOR FRESH AIR
UNTIL THE IRRITATION CEASES. IF IRRITATION
CONTINUES, SEE A PHYSICIAN.
DO NOT USE A REPLACEMENT AIRBAG THAT IS
NOT IN THE ORIGINAL PACKAGING, IMPROPER
DEPLOYMENT AND PERSONAL INJURY CAN
RESULT.
THE FACTORY INSTALLED FASTENERS,
SCREWS AND BOLTS USED TO FASTEN AIRBAG
COMPONENTS HAVE A SPECIAL COATING AND
ARE SPECIFICALLY DESIGNED FOR THE AIRBAG
SYSTEM. DO NOT USE SUBSTITUTE FASTENERS,
USE ONLY ORIGINAL EQUIPMENT FASTENERS
LISTED IN THE PARTS CATALOG WHEN FASTENER
REPLACEMENT IS REQUIRED.
NOTE: Airbags should be stored in a cool dry loca-
tion away from excessive heat and static electrical
activity with the fabric airbag facing UP, or a prema-
ture deployment can result.
If the Driver/Passenger Airbag Module is defective
and not deployed, refer to Chrysler Corporation cur-
rent return list for proper handling procedures.
AIRBAG CONTROL MODULE (ACM)
The Ai rbag Control Modul e (ACM) contai ns the
i mpact sensor and energy reserve capaci tor. The
NS RESTRAINT SYSTEM 8M - 1
ACM moni tors the system to determi ne the system
readi ness. The ACM contai ns on-board di agnosti cs
and wi l l l i ght the AI RBAG warni ng l amp i n the mes-
sage center when a probl em occurs.
The dri ver and passenger ai rbag system i s a safety
devi ce desi gned to reduce the ri sk of fatal i ty or seri -
ous i njury, caused by a frontal i mpact of the vehi cl e.
The i mpact sensor provi des veri fi cati on of the
di recti on and severi ty of the i mpact. One i mpact sen-
sor i s used. I t i s l ocated i nsi de the Ai rbag Control
Modul e (ACM) whi ch i s mounted on a bracket, just
forward of the center consol e. The i mpact sensor i s
an accel erometer that senses decel erati on. The decel -
erati on pul ses are sent to a mi croprocessor whi ch
contai ns a deci si on al gori thm. When an i mpact i s
severe enough to requi re ai rbag protecti on, the ACM
mi cro processor sends a si gnal that compl etes the
el ectri cal ci rcui t to the dri ver and passenger ai rbags.
The sensor i s cal i brated for the speci fi c vehi cl e and
reacts to the severi ty and di recti on of the i mpact.
CLOCKSPRING
The cl ockspri ng i s snapped i nto a pl asti c mounti ng
pl atform on the steeri ng col umn behi nd the steeri ng
wheel . The cl ockspri ng i s used to mai ntai n a conti n-
uous el ectri cal ci rcui t between the wi ri ng harness
and the dri vers ai rbag modul e. Thi s assembl y con-
si sts of a fl at ri bbon l i ke el ectri cal l y conducti ve tape
whi ch wi nds and unwi nds wi th the steeri ng wheel
rotati on.
DRIVER AND PASSENGER AIRBAG MODULES
The Dri ver Ai rbag Modul e i s l ocated i n the center
of the steeri ng wheel . The Passenger Ai rbag Modul e
i s l ocated i n the i nstrument panel above the gl ove
box (Fi g. 1). The Dri ver Ai rbag Modul e cover contai ns
the horn swi tch, i nfl ator devi ce, and a fabri c bag. The
ai rbag cover/horn swi tch i s servi ced separatel y from
the i nfl ator and bag components. Refer to Group 8G,
Horns for proper servi ce procedure for horn swi tch.
The Passenger Ai rbag Modul e i s servi ced as an
assembl y.
WARNING: WHEN THE AIRBAG SYSTEM IS
DEPLOYED BECAUSE OF A COLLISION, THE FOL-
LOWING MUST BE REPLACED:
COMPLETE STEERING COLUMN ASSEMBLY
LOWER STEERING COUPLER
STEERING WHEEL
STEERING COLUMN CLOCKSPRING
DRIVER AIRBAG COVER/HORN SWITCH
DRIVER AIRBAG MODULE
PASSENGER AIRBAG MODULE
UPPER INSTRUMENT PANEL WITH PAD
AIRBAG SYSTEM TEST
cabl e.
WARNING: DISCONNECT AND ISOLATE THE BAT-
TERY NEGATIVE CABLE BEFORE BEGINNING AIR-
BAG SYSTEM COMPONENT SERVICE
PROCEDURES. THIS WILL DISABLE THE AIRBAG
SYSTEM. FAILURE TO DISCONNECT THE BATTERY
COULD RESULT IN ACCIDENTAL AIRBAG DEPLOY-
MENT AND POSSIBLE PERSONAL INJURY. ALLOW
SYSTEM CAPACITOR TO DISCHARGE FOR TWO
MINUTES BEFORE REMOVING AIRBAG COMPO-
NENTS.
(2) Connect scan tool (DRB) to Data Li nk connec-
tor, l ocated at l eft si de of the steeri ng col umn and at
the l ower edge of the l ower i nstrument panel .
(3) Turn the i gni ti on key to ON posi ti on. Exi t vehi -
cl e wi th scan tool . Use the l atest versi on of the
proper cartri dge.
(4) After checki ng that no one i s i nsi de the vehi cl e,
connect the battery negati ve termi nal .
(5) Usi ng the scan tool , read and record acti ve
di agnosti c code data.
(6) Read and record any stored di agnosti c codes.
(7) Refer to the proper Body Di agnosti c Procedures
Manual i f any di agnosti c codes are found i n Step 5 or
Step 6.
(8) Erase stored di agnosti c codes i f there are no
acti ve di agnosti c codes. I f probl ems remai n, di agnos-
ti c codes wi l l not erase. Refer to the Passi ve
Restrai nt Di agnosti c Test Manual to di agnose the
probl em. If airbag warning lamp either fails to
light, or goes on and stays on, there is a system
malfunction. Refer to the proper Body Diagnos-
tic Procedures Manual to diagnose the problem.
Fig. 1 Airbag Module Locations
8M - 2 RESTRAINT SYSTEM NS
SERVICE PROCEDURES
CLEANUP PROCEDURE
Rol l or fol d the passenger ai rbag towards the
i nstrument panel surface and cl ose the door over the
fol ded bag. Then tape the door shut.
Use a vacuum cl eaner to remove any resi dual pow-
der from the vehi cl e i nteri or. Work from the outsi de
i n to avoi d kneel i ng or si tti ng i n a contami nated
area. Vacuum the heater and A/C outl ets as wel l (Fi g.
2). I f HVAC was i n RECI RC mode at ti me of ai rbag
depl oyment, operate HVAC bl ower on l ow speed/heat
and vacuum powder resi due expel l ed from the heat
outl ets. Mul ti pl e vacuum cl eani ng may to necessary
to decontami nate the i nteri or of the vehi cl e.
NOTE: Dispose deployed airbag properly, contact
dealer or government agency for disposal recom-
mendations.
SERVICE OF DEPLOYED AIRBAG MODULE
DRIVER AIRBAG
I f a Dri ver Ai rbag Modul e has been depl oyed, but
not due to a col l i si on, repl ace the fol l owi ng:
Dri ver Ai rbag Modul e
Cl ockspri ng assembl y
Dri ver ai rbag cover/horn swi tch
The components above must be repl aced because
they cannot be reused. Repl ace any other dri ver ai r-
bag system components i f damaged.
PASSENGER AIRBAG
I f a Passenger Ai rbag Modul e has been depl oyed,
but not due to a col l i si on, repl ace the fol l owi ng:
Passenger Ai rbag Modul e
Upper i nstrument panel wi th pad
The component above must be repl aced because
they cannot be reused. I nspect the heat duct near the
passenger ai rbag for any damage repl ace as neces-
sary. Repl ace any other passenger ai rbag system
components i f damaged.
HANDLING AIRBAG MODULE
DEPLOYED MODULE
The vehi cl e i nteri or may contai n a very smal l
amount of sodi um hydroxi de powder, a by-product of
ai rbag depl oyment. Sodi um hydroxi de powder can
i rri tate the ski n, eyes, nose and throat. Wear safety
gl asses, rubber gl oves, and l ong sl eeved cl othi ng
when cl eani ng any of the powder resi due from the
vehi cl e.
I f you fi nd that the cl eanup i s i rri tati ng your ski n,
run cool water over the affected area. Al so, i f you
experi ence nasal or throat i rri tati on, exi t the vehi cl e
for fresh ai r unti l the i rri tati on ceases. I f i rri tati on
conti nues, see a physi ci an.
UNDEPLOYED
The ai rbag modul es must be stored i n i ts ori gi nal
speci al contai ner unti l used for servi ce. At no ti me
shoul d a source of el ectri ci ty be permi tted near the
i nfl ator on the back of an ai rbag modul e. When car-
ryi ng or handl i ng an undepl oyed ai rbag modul e, the
tri m si de of the ai rbag shoul d be poi nti ng away from
the body to mi ni mi ze possi bi l i ty of i njury i f acci den-
tal depl oyment occurs. Do not pl ace undepl oyed ai r-
bag face down on a sol i d surface, the ai rbag wi l l
propel i nto the ai r i f acci dental l y depl oyment occurs.
AIRBAG CONTROL MODULE
WARNING: THE ACM CONTAINS THE IMPACT
SENSOR WHICH ENABLES THE SYSTEM TO
DEPLOY THE AIRBAGS. TO AVOID ACCIDENTAL
DEPLOYMENT, NEVER CONNECT ACM ELECTRI-
CALLY TO THE SYSTEM WHILE VEHICLE BATTERY
IS CONNECTED. DISCONNECT AND ISOLATE THE
BATTERY NEGATIVE CABLE BEFORE BEGINNING
ANY AIRBAG SYSTEM COMPONENT SERVICE PRO-
CEDURES. THIS WILL DISABLE THE AIRBAG SYS-
TEM. FAILURE TO DISCONNECT THE BATTERY
NENTS.
REMOVAL
Al l ow at l east two mi nutes for the reserve capaci tor
i n the Ai rbag Control Modul e (ACM) to di scharge.
Fig. 2 Vacuum Heater and A/C Outlets
(2) Remove forward l ower consol e from i nstrument
panel , refer to Group 8E, I nstrument Panel and Sys-
tems for proper procedures.
(3) Remove screw hol di ng l ower heat duct to
i nstrument panel support (Fi g. 3).
(4) Remove heat duct from i nstrument panel .
(5) Remove two bol ts hol di ng top of ri ght support
to i nstrument panel (Fi g. 4).
(6) Remove two bol ts hol di ng bottom of ri ght sup-
port to fl oor pan.
(7) Separate ri ght i nstrument panel support from
vehi cl e.
(8) Di sconnect two wi re connectors from ACM (Fi g.
5).
(9) Remove four bol ts hol di ng the ACM bracket
assembl y to fl oor (Fi g. 6).
(10) Remove the ACM from vehi cl e.
INSTALLATION
WARNING: DO NOT REMOVE THE BOLTS HOLD-
ING THE ACM TO THE ACM BRACKET. THESE
BOLTS ARE SAFETY TORQUED AT THE MANUFAC-
TURING FACILITY AND SHOULD NOT BE REMOVED
FOR ANY REASON. THE NEW ACM WILL COME
WITH A NEW BRACKET INSTALLED.
CAUTION: USE CORRECT SCREWS WHEN
INSTALLING THE ACM
Attach the ACM bracket assembl y to vehi cl e wi th the
proper screws and ti ghten to 805 to 11.9 Nm (75 to
105 i n. l bs.) torque. Do not connect battery negati ve
cabl e. Refer to Di agnosi s and Testi ng for Ai rbag Sys-
tem Test procedures.
Fig. 3 Heat Duct
Fig. 4 Instrument Panel Supports
Fig. 5 ACM Connectors
Fig. 6 ACM Bracket Assembly
CLOCKSPRING
NENTS.
REMOVAL
(1) Posi ti on steeri ng wheel and front wheel s
strai ght ahead.
i n the ACM to di scharge.
(4) Remove dri ver ai rbag from steeri ng wheel (Fi g.
7).
(5) Di sconnect wi re connectors from back of ai rbag
modul e.
(6) Remove steeri ng wheel (Fi g. 8).
(7) Remove steeri ng col umn shrouds (Fi g. 9).
(8) Di sconnect 2-way and 4-way connectors
between the cl ockspri ng and the i nstrument panel
wi ri ng harness.
(9) Remove cl ockspri ng from housi ng assembl y by
depressi ng the two tabs on the cl ockspri ng (Fi g. 10)
INSTALLATION
For i nstal l ati on, reverse the above procedures. Do
not connect battery negati ve cabl e. Refer to Di agno-
si s and Testi ng for Ai rbag System Test procedures.
DRIVER AIRBAG MODULE
NENTS.
Fig. 7 Airbag/Horn Switch
Fig. 8 Steering Wheel
Fig. 9 Airbag Clockspring
DEPLOYED MODULE
The Dri ver Ai rbag Modul e and Dri ver Ai rbag Cov-
er/Horn Pad are servi ced separatel y from eachother.
REMOVAL
(1) Di sconnect battery negati ve cabl e. Al l ow at
l east two mi nutes for the reserve capaci tor i n the
ACM to di scharge.
(2) Cl ean powder resi due from i nteri or of vehi cl e,
refer to Cl eanup Procedure.
(3) Remove three screws attachi ng Dri ver Ai rbag
Modul e to steeri ng wheel (Fi g. 7).
(4) Remove ai rbag modul e from steeri ng wheel .
(5) Di sconnect wi re connectors from Ai rbag Mod-
ul e, horn swi tch, and speed control swi tches.
(6) Adjust the steeri ng wheel so that the ti res are
i n a strai ght ahead posi ti on. Remove steeri ng wheel
(Fi g. 8), refer to Group 19, Steeri ng for proper proce-
dure.
(7) Di sconnect the 2-way and 4-way connectors
between the cl ockspri ng and the i nstrument panel
wi ri ng harness.
shrouds.
(9) Remove cl ockspri ng from the housi ng assembl y
by depressi ng the 2 tabs on the cl ockspri ng (Fi g. 10).
(10) Remove screws hol di ng speed control swi tches
to ai rbag cover and remove, i f equi pped.
INSTALLATION
UNDEPLOYED
REMOVAL
Ai rbag Control Modul e (ACM) to di scharge.
(2) Remove screws attachi ng ai rbag/horn swi tch to
steeri ng wheel (Fi g. 7).
(3) Remove Dri ver Ai rbag Modul e from steeri ng
wheel .
(4) Di sconnect wi re connectors from ai rbag mod-
ul e, horn swi tch, and speed control swi tches, i f
equi pped.
(5) Remove screws hol di ng vehi cl e speed control
swi tches to ai rbag cover and remove.
INSTALLATION
For i nstal l ati on, reverse the above procedures and
do not connect battery negati ve cabl e. Do not connect
battery negati ve cabl e. Refer to Di agnosi s and Test-
i ng for Ai rbag System Test procedures.
PASSENGER AIRBAG
NENTS.
DEPLOYED MODULE
REMOVAL
i n the Ai rbag Control Modul e to di scharge.
(2) Cl ean powder resi due from i nteri or of vehi cl e,
refer to Cl eanup Procedure i n thi s secti on.
(3) Remove i nstrument panel , refer to Group 8E,
I nstrument Panel and Systems for proper proce-
dures.
(4) Remove al l reusabl e components from the
upper i nstrument panel .
INSTALLATION
Transfer al l reusabl e components to the new the
upper i nstrument panel .
(1) I nstal l new Passenger Ai rbag Modul e i nto
i nstrument panel .
(2) I nstal l ai rbag modul e attachi ng screws to the
i nstrument panel .
Fig. 10 Clockspring Locking Tabs
(3) I nstal l I nstrument panel . Refer to Group 8E,
I nstrument Panel and Systems for i nstal l ati on proce-
dures.
(4) Through access hol es i n i nstrument panel
above gl ove box openi ng, i nstal l screws hol di ng ai r-
bag to back of panel .
(5) I nstal l the bol ts attachi ng forward ai rbag
mount to the i nstrument panel (Fi g. 11).
(6) Connect yel l ow wi re connector from passenger
ai rbag.
(7) I nstal l the gl ove box.
(8) I nstal l ri ght front i nstrument panel speaker.
(10) Do not connect battery negati ve cabl e. Refer
to Di agnosi s and Testi ng for Ai rbag System Test pro-
cedures.
UNDEPLOYED
REMOVAL
ACM to di scharge.
(2) Remove i nstrument panel top cover.
(3) Remove ri ght front i nstrument panel speaker.
(5) Di sconnect yel l ow wi re connector from passen-
ger ai rbag.
(6) Remove bol ts attachi ng forward ai rbag mount
to the i nstrument panel
(7) Through access hol es i n i nstrument panel
above gl ove box openi ng, remove screws hol di ng ai r-
bag to back of panel .
(8) Remove screws attachi ng ai rbag to upper
i nstrument panel .
(9) Remove ai rbag from i nstrument panel through
top of i nstrument panel .
INSTALLATION
ADJ USTMENTS
CLOCKSPRING CENTERING PROCEDURE
I f the rotati ng tape (wi re coi l ) i n the cl ockspri ng i s
not posi ti oned properl y wi th the steeri ng wheel and
the front wheel s, the cl ockspri ng may fai l . The fol -
l owi ng procedure MUST BE USED to center the
cl ockspri ng i f i t i s not known to be properl y posi -
ti oned, or i f the front wheel s were moved from the
strai ght ahead posi ti on.
NENTS.
(1) Adjust the steeri ng wheel so that the ti res are
i n a strai ght ahead posi ti on.
i n the ACM to di scharge.
(3) Remove Dri ver Ai rbag Modul e from steeri ng
wheel .
(4) Di sconnect wi re connectors from back of ai rbag
modul e.
(5) Remove steeri ng wheel .
(6) Depress the two pl asti c l ocki ng pi ns to di sen-
gage l ock mechani sm (Fi g. 10).
(7) Wi th l ock mechani sm di sengaged, rotate the
cl ockspri ng rotor cl ockwi se unti l the rotor stops. Do
not appl y excessi ve force.
(8) From the end of travel , rotate the rotor three
turns countercl ockwi se. The wi res shoul d end up at
the top. Rel ease l ocki ng pi ns to engage cl ockspri ng
l ock mechani sm.
(9) I nstal l steeri ng wheel and ai rbag.
(10) Do not connect battery negati ve cabl e. Refer
to Di agnosi s and Testi ng for Ai rbag System Test
procedures.
Fig. 11 Airbag Upper Attachment
ELECTRICALLY HEATED SYSTEMS
CONTENTS
page page
HVAC MOUNTED SWITCH . . . . . . . . . . . . . . . . . 1
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . 1
GRID LINE TEST . . . . . . . . . . . . . . . . . . . . . . . . . 2
SYSTEM TEST . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SERVICE PROCEDURES
GRID LINE AND TERMINAL REPAIR . . . . . . . . . 3
INTRODUCTION
The el ectri cal l y heated Rear Wi ndow Defogger (Fi g.
1), Heated Power Si de Vi ew Mi rrors, and Heated
Wi ndshi el d Wi per De-i cer (Fi g. 2) i s avai l abl e on NS
vehi cl es.
The Rear Wi ndow Defogger system consi sts of two
verti cal bus bars l i nked by a seri es of gri d l i nes on
the i nsi de surface of the rear wi ndow. The el ectri cal
ci rcui t consi sts of the rear defogger swi tch i n the
HVAC and a rel ay wi th ti mer swi tch to turn OFF the
system after ten mi nutes. The mai n feed ci rcui t i s
protected by fuse one (40 amp) i n the Juncti on Bl ock.
The rear defogger swi tch and rel ay al so acti vates the
heated power si de vi ew mi rrors and heated wi nd-
shi el d wi per de-i cer. The HVAC rear defogger swi tch
i s protected by fuse ten (10 amp) i n the Juncti on
Bl ock. The heated mi rror ci rcui t i s protected by fuse
12 (10 amp) i n the juncti on bl ock. The heated wi nd-
shi el d wi per de-i cer ci rcui t i s protected by fuse 21 (25
amp) i n the Juncti on Bl ock.
The Heated Wi ndshi el d Wi per Dei cer i s al so acti -
vated when the DEFROST mode i s sel ected on the
HVAC. I n the DEFROST mode the rear defogger
rel ay/ti mer i s bypassed, the heated wi ndshi el d wi per
de-i cer wi l l stay ON unti l the another mode i s
sel ected. For ci rcui t i nformati on and component l oca-
ti on refer to Group 8W, Wi ri ng Di agrams.
CAUTION: Since grid lines can be damaged or
scraped off with sharp instruments, care should be
taken in cleaning the glass or removing foreign
materials, decals or stickers. Normal glass cleaning
solvents or hot water used with rags or toweling is
recommended.
HVAC MOUNTED SWITCH
The rear wi ndow defogger swi tch i s i ntegrated i nto
the HVAC (Fi g. 3). An LED i ndi cator wi l l i l l umi nate
when the swi tch i s acti vated. The swi tch energi zes
the ti mi ng ci rcui t and acti vates the rear wi ndow
defogger rel ay. The rel ay control s the current to fl ow
to the gri ds of the rear wi ndow defogger, heated
power si de vi ew mi rrors and the heated wi ndshi el d
wi per de-i cer. The defogger rel ay wi l l be on for
approxi matel y 10 mi nutes or unti l the control swi tch
or i gni ti on i s turned off.
Fig. 1 Rear Window Defogger
Fig. 2 Heated Windshield Wiper De-icer
NS ELECTRICALLY HEATED SYSTEMS 8N - 1
SYSTEM TEST
El ectri cal l y heated rear wi ndow defogger or the
heated wi ndshi el d wi per dei cer operati on can be
checked on the vehi cl e i n the fol l owi ng manner:
(1) Turn the i gni ti on swi tch to the ON posi ti on.
(2) Usi ng a ammeter on the battery, turn the rear
defogger control swi tch to the ON posi ti on, a di sti nct
i ncrease i n amperage draw shoul d be noted.
(3) The rear wi ndow defogger or the heated wi nd-
shi el d wi per dei cer operati on can be checked by feel -
i ng the gl ass. A di sti nct di fference i n temperature
between the gri d l i nes and adjacent cl ear gl ass can
be detected i n 3 to 4 mi nutes of operati on.
(4) Usi ng a DC vol tmeter (Fi g. 4) contact termi nal
B wi th the negati ve l ead, and termi nal A wi th the
posi ti ve l ead. The vol tmeter shoul d read 10-14 vol ts.
(5) I ndi cator l i ght i l l umi nati on means that there i s
power avai l abl e at the swi tch onl y and does not nec-
essari l y veri fy system operati on.
(6) I f turni ng the defogger swi tch ON, no di sti nct
current draw on the ammeter the probl em shoul d be
i sol ated i n the fol l owi ng manner:
Confi rm that i gni ti on swi tch i s ON.
Ensure that the heated rear wi ndow or the
heated wi ndshi el d wi per dei cer feed pi gtai l i s con-
nected to the wi ri ng harness and that the ground
pi gtai l i s i n fact grounded.
Ensure that the proper fuse i n the Juncti on
Bl ock i s OK.
(7) When the above steps have been compl eted and
the system i s sti l l i noperati ve, one or more of the fol -
l owi ng i s defecti ve:
HVAC swi tch
Rear wi ndow defogger rel ay i n the rel ay bank.
Check for l oose connector or a wi re pushed out
of connector.
Rear wi ndow or the wi ndshi el d gri d l i nes (al l
gri d l i nes woul d have to be broken, or one of the feed
pi gtai l s not connected to the bus bar, for no ammeter
defl ecti on).
(8) I f turni ng the swi tch ON produces severe vol t-
meter defl ecti on, the ci rcui t shoul d be cl osel y checked
for a shorti ng condi ti on.
(9) I f the system operati on has been veri fi ed but
i ndi cator LED does not l i ght, repl ace swi tch.
(10) For detai l ed wi ri ng i nformati on, refer to
Group 8W, Wi ri ng Di agrams.
GRID LINE TEST
The hori zontal gri d l i nes and verti cal bus bar l i nes
pri nted and baked on i nsi de surface of the wi ndow
gl ass makes up an el ectri cal paral l el ci rcui t. The
el ectri cal l y conducti ve l i nes are composed of a si l ver
cerami c materi al whi ch when baked on gl ass
becomes bonded to the gl ass and i s hi ghl y resi stant
to abrasi on. I t i s possi bl e, however, that a break may
exi st or occur i n an i ndi vi dual gri d l i ne resul ti ng i n
no current fl ow through the l i ne. To detect breaks i n
gri d l i nes, the fol l owi ng procedure i s requi red:
(1) Turn i gni ti on and rear wi ndow defogger control
swi tch ON. The i ndi cator l i ght shoul d come on.
(2) Usi ng a DC vol tmeter wi th 0-15 vol t range,
contact verti cal bus bar connecti ng gri d l i nes on pas-
senger si de of vehi cl e at termi nal A wi th negati ve
l ead of vol tmeter (Fi g. 4). Wi th posi ti ve l ead of vol t-
meter, contact verti cal bus bar on dri ver si de of vehi -
cl e at termi nal B. The vol tmeter shoul d read 10-14
vol ts.
Fig. 3 HVAC Rear Window Defogger Switch
Fig. 4 Grid Line Test
8N - 2 ELECTRICALLY HEATED SYSTEMS NS
(3) Wi th negati ve l ead of vol tmeter, contact a good
body ground poi nt. The vol tage readi ng shoul d not
change. A di fferent readi ng i ndi cates a poor ground
connecti on.
(4) Connect negati ve l ead of vol tmeter to termi nal
A on passenger si de bus bar and touch each gri d l i ne
at Mi d-Poi nt wi th posi ti ve l ead. A readi ng of approx-
i matel y 6 vol ts i ndi cates a l i ne i s good. A readi ng of 0
vol ts i ndi cates a break i n l i ne between Mi d-Poi nt C
and termi nal B. A readi ng of 10-14 vol ts i ndi cates a
break between Mi d-Poi nt C and ground termi nal A.
Move toward break and vol tage wi l l change as soon
as break i s crossed.
SERVICE PROCEDURES
GRID LINE AND TERMINAL REPAIR
WARNING: REPAIR KIT MAY CAUSE SKIN OR EYE
IRRITATION. CONTAINS EPOXY RESIN AND AMINE
TYPE HARDENER, HARMFUL IF SWALLOWED.
AVOID CONTACT WITH SKIN AND EYES. FOR SKIN,
WASH AFFECTED AREAS WITH SOAP AND WATER.
DO NOT TAKE INTERNALLY. IF TAKEN INTER-
NALLY, INDUCE VOMITING; CALL A PHYSICIAN
IMMEDIATELY. IF IN CONTACT WITH EYES, FLUSH
WITH PLENTY OF WATER. USE WITH ADEQUATE
VENTILATION. DO NOT USE NEAR FIRE OR FLAME.
CONTENTS CONTAINS 3% FLAMMABLE SOL-
VENTS. KEEP OUT OF REACH OF CHILDREN.
The repai r for the front wi ndshi el d or the rear wi n-
dow gri ds are the same.
The repai r of gri d l i nes and repl acement of the ter-
mi nal i s possi bl e usi ng the Mopar Repai r Package
or equi val ent.
(1) Cl ean area surroundi ng gri d l i ne or termi nal
by gentl y rubbi ng area wi th steel wool .
(2) Wi pe area wi th cl ean cl oth soaked i n al cohol or
si mi l ar sol vent. I t i s necessary that al l contami nants
be removed from repai r area.
(3) Remove package separator cl amp and mi x pl as-
ti c conducti ve epoxy thoroughl y.
(4) For gri d l i ne, mark off area to be repai red wi th
maski ng tape (Fi g. 5).
(5) Appl y conducti ve epoxy through sl i t i n maski ng
tape. Overl ap both ends of the break.
(6) For a termi nal repl acement, appl y a thi n l ayer
of epoxy to area where termi nal was fastened.
(7) Appl y a thi n l ayer of epoxy on termi nal and
pl ace termi nal on desi red l ocati on. To prevent termi -
nal from fal l i ng off use a wooden wedge to secure i t.
(8) Careful l y remove maski ng tape from gri d l i ne.
CAUTION: Do not allow the laminated windshield
glass surface to exceed 82 C (180 F) or the glass
may fracture. The rear window glass surface should
not exceed 204 C (400 F).
(9) Al l ow epoxy to cure 24 hours at room tempera-
ture.
(10) After epoxy i s properl y cured remove wedge
from termi nal and check the operati on of the rear
wi ndow defogger.
Fig. 5 Grid Line Repair
NS ELECTRICALLY HEATED SYSTEMS 8N - 3
POWER DOOR LOCKS
CONTENTS
page page
POWER DOOR LOCKS . . . . . . . . . . . . . . . . . . . . . 1 REMOTE KEYLESS ENTRY . . . . . . . . . . . . . . . . . . 5
POWER DOOR LOCKS
INDEX
page page
GENERAL INFORMATION
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . 1
AUTOMATIC DOOR LOCK FEATURE . . . . . . . . . . 1
DOOR LOCK CIRCUIT PROTECTION . . . . . . . . . 1
DOOR LOCK INHIBIT FEATURE . . . . . . . . . . . . . 2
SLIDING DOOR LOCK MEMORY FEATURE . . . . . 2
AUTOMATIC DOOR LOCK SYSTEM TEST . . . . . . 2
DOOR LOCK MOTOR . . . . . . . . . . . . . . . . . . . . . 2
DOOR LOCK SWITCH TEST . . . . . . . . . . . . . . . . 2
SERVICE PROCEDURES
AUTOMATIC DOOR LOCKS
DISABLE OR ENABLE . . . . . . . . . . . . . . . . . . . . 3
FRONT DOOR LOCK MOTOR/LATCH . . . . . . . . . 3
LIFTGATE LOCK MOTOR . . . . . . . . . . . . . . . . . . . 3
SLIDING DOOR LOCK CONTACTS . . . . . . . . . . . 3
SLIDING DOOR LOCK MOTOR . . . . . . . . . . . . . . 4
SLIDING DOOR LOCK PLUNGER . . . . . . . . . . . . 4
GENERAL INFORMATION
INTRODUCTION
The Body Control Modul e (BCM) l ocks or unl ocks
the doors when an actuati on i nput si gnal from a door
l ock swi tch or Remote Keyl ess Entry Modul e (RKE)
i s recei ved. The BCM si gnal s l ock and unl ock rel ays
i n the Juncti on Bl ock to actuate the door l ock motors.
The front doors, sl i di ng door(s) and l i ftgate are
equi pped wi th actuator motors to l ock or unl ock the
l atch mechani sms. The front door l ock actuator motor
i s not servi ced separatel y from the door l atch. The
BCM l ocks the doors and l i ftgate automati cal l y when
the vehi cl e i s dri ven beyond the speed of 25.7 Km/h
(16 mph). The automati c door l ock feature can be di s-
abl ed i f desi red. Al l doors and l i ftgate can be l ocked
or unl ocked usi ng mechani cal button or key cyl i nder
methods.
AUTOMATIC DOOR LOCK FEATURE
The vehi cl e comes wi th two opti ons for power door
l ocks:
Rol l i ng automati c l ock (ENABLE), doors auto-
mati cal l y l ock at approxi matel y at 25.7 Km/h (16
mph).
No rol l i ng automati c l ock (DI SABLE), doors do
not automati cal l y l ock when the vehi cl e i s movi ng.
The BCM i s equi pped wi th a di sabl e feature to
stop the speed sensi ti ve automati c door l ocks from
functi oni ng. The DI SABLE feature can be swi tched
ON or OFF as desi red. When the system i s DI S-
ABLED the door l ocks wi l l operate normal l y, but wi l l
not l ock automati cal l y when the vehi cl e i s rol l i ng.
When the door l ocks are ENABLED the door l ocks
wi l l automati cal l y l ock when the vehi cl e i s movi ng at
about 25.7 Km/h (16 mph).
DOOR LOCK CIRCUIT PROTECTION
The BCM control s the door l ock rel ays operati on.
I f the door l ock swi tch i s actuated conti nuousl y for
more than one second the BCM wi l l i nterrupt the
rel ay ci rcui t. The door l ock system i s protected by a
40 amp fuse l ocated i n the Power Di stri buti on Center
(PDC). The LOCK and UNLOCK rel ays are l ocated
i n the Juncti on Bl ock. The Power Di stri buti on Center
i s l ocated al ong si de of the battery. The l ock motors
are protected wi th Posi ti ve Temperature Coeffi ci ent
(PTC) devi ce that prevents motor burn out.
NS POWER DOOR LOCKS 8P - 1
DOOR LOCK INHIBIT FEATURE
The BCM cancel s out the door l ock swi tch actua-
ti on, when the key i s i n the I gni ti on Swi tch and a
door i s open. After the key i s removed from the I gni -
ti on Swi tch, or the doors are cl osed, the power door
l ocks wi l l operate normal l y.
SLIDING DOOR LOCK MEMORY FEATURE
The door l ocks on the sl i di ng door(s) can be actu-
ated when the door(s) are cl osed. I f the sl i di ng
door(s) are open when the door l ocks are actuated,
the BCM wi l l hol d the l ock command i n memory
unti l the door(s) i s cl osed. When the door i s cl osed
and the door jamb termi nal s make contact, si gnal i ng
the BCM to l ock the sl i di ng door(s) automati cal l y.
Actuati ng the door l ock swi tch to the unl ock posi ti on
before the sl i di ng door(s) are cl osed wi l l cancel the
l ock request.
AUTOMATIC DOOR LOCK SYSTEM TEST
When usi ng a scan tool (DRB) for testi ng the auto-
mati c door l ock system, refer to the Body Di agnosti c
Procedures Manual . Refer to Group 8W, Wi ri ng Di a-
grams for ci rcui t i nformati on and component l oca-
ti ons.
DOOR LOCK MOTOR
Veri fy battery condi ti on before testi ng door l ock
motor(s), refer to Group 8A, Battery for proper di ag-
nosi s procedures.
To determi ne whi ch motor i s faul ty, check each
i ndi vi dual door for el ectri cal l ock and unl ock or di s-
connect the motor connectors one at a ti me, whi l e
operati ng the door l ock swi tch. I n the event that
none of the motors work, the probl em may be caused
by a shorted motor, a rel ay or a bad swi tch. Di scon-
necti ng the defecti ve motor wi l l al l ow the others to
work.
To test an i ndi vi dual door l ock motor, di sconnect
the el ectri cal connector from the motor. To l ock the
door, connect a 12 vol t power source to the posi ti ve
pi n of the l ock motor and a ground wi re to the other
pi n (Fi g. 1), (Fi g. 2), (Fi g. 3) and refer to Group 8W,
Wi ri ng Di agrams for pi n l ocati ons. To unl ock the door
reverse the wi re connecti ons at the motor pi n termi -
nal s. I f these resul ts are NOT obtai ned, repl ace the
motor.
DOOR LOCK SWITCH TEST
(1) Remove door l ock swi tch bezel assembl y from
door. Refer to Group 23, Body for removal proce-
dures.
(2) Di sconnect wi re connector from back of door
l ock swi tch.
(3) Depress swi tch to LOCK posi ti on.
(4) Usi ng an ohmmeter, test swi tch resi stance
between Pi ns 2 and 3. Refer to Door Lock Swi tch
Test and (Fi g. 4).
(5) Depress swi tch to UNLOCK posi ti on.
(6) Test resi stance between Pi ns 2 and 3.
(7) I f resi stance val ues are not wi thi n the param-
eters shown repl ace the door l ock swi tch.
Fig. 1 Sliding Door Lock MotorTypical
Fig. 2 Front Door Lock Motor
8P - 2 POWER DOOR LOCKS NS
SERVICE PROCEDURES
AUTOMATIC DOOR LOCKS DISABLE OR ENABLE
The vehi cl e comes wi th two opti ons for power door
l ocks:
Rol l i ng automati c l ock, ENABLE approxi matel y
at 16 mph.
No rol l i ng automati c l ock, DI SABLE.
To change the automati c door l ock sel ecti on, do the
fol l owi ng:
(1) Cl ose al l doors.
(2) Pl ace the i gni ti on key i n the OFF posi ti on for
20 seconds or more.
(3) Turn i gni ti on key to the run posi ti on and to the
OFF posi ti on wi thout cranki ng the engi ne four ti mes.
The mal functi on l amp wi l l come on each ti me the key
i s i n the run posi ti on.
(4) Press the door l ock button to l ock the doors.
Thi s procedure reverses the automati c door l ock
opti on, Enabl e to Di sabl e, or Di sabl e to Enabl e. I f the
present opti on i s undesi rabl e, repeat to arri ve at the
desi red opti on.
FRONT DOOR LOCK MOTOR/LATCH
Refer to Group 23, Body for proper servi ce proce-
dures.
LIFTGATE LOCK MOTOR
REMOVAL
(2) Remove bol ts hol di ng l i ftgate l ock motor to l i ft-
gate (Fi g. 5).
(3) Di sconnect the wi re connector from power l ock
motor.
(4) Di sconnect the l i ftgate l ock motor from outsi de
handl e l ock l i nk.
(5) Remove the l i ftgate l ock motor from vehi cl e.
INSTALLATION
SLIDING DOOR LOCK CONTACTS
REMOVAL
(1) Open the sl i di ng door.
(2) Remove screw hol di ng the l ock contacts to
B-pi l l ar (Fi g. 6).
(3) Di sconnect the wi re connector from the l ock
contacts.
(4) Remove the l ock contacts from B-pi l l ar.
INSTALLATION
Fig. 3 Lift Gate Release Assembly
Fig. 4 Door Lock Switch
DOOR LOCK SWITCH TEST
SWITCH
POSITION
CONTINUITY
BETWEEN
RESISTANCE
VALUE
LOCK 2 and 3 1.5K Ohm 1%
UNLOCK 2 and 3 249 Ohm 1%
Fig. 5 Liftgate Lock Motor
SLIDING DOOR LOCK MOTOR
REMOVAL
(1) Remove sl i di ng door tri m panel .
(2) Remove watershi el d as necessary.
(3) Remove l atch/l ock control cover.
(4) Remove l atch/l ock control .
(5) Remove screws hol di ng door l ock motor to
l atch/l ock control (Fi g. 7).
(6) Remove l ock motor from control .
INSTALLATION
SLIDING DOOR LOCK PLUNGER
REMOVAL
(2) Remove watershi el d as necessary to gai n access
to push-i n fasteners hol di ng sl i di ng door l ock pl unger
wi ri ng harness to i nner door panel .
(3) Make note of wi ri ng harness routi ng to ai d
i nstal l ati on (Fi g. 8).
(4) Remove push-i n fasteners hol di ng l ock pl unger
wi ri ng harness to i nner door panel .
(5) Di sconnect pl unger wi ri ng harness from sl i di ng
door l ock motor.
(6) Remove screw hol di ng l ock pl unger to door
frame (Fi g. 8).
(7) Remove l ock pl unger from sl i di ng door.
INSTALLATION
Fig. 6 Sliding Door Lock Contacts
Fig. 7 Sliding Door Lock Motor
Fig. 8 Sliding Door Lock Plunger
REMOTE KEYLESS ENTRY
INDEX
page page
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . 5
VEHICLE ACCESS CODE (VAC)
PROGRAMMING . . . . . . . . . . . . . . . . . . . . . . . . 5
RKE DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . 5
SERVICE PROCEDURES
HORN CHIRP DISABLE OR ENABLE . . . . . . . . . . 6
RKE MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
ADJUSTMENTS
PROGRAMMING RKE MODULE . . . . . . . . . . . . . . 6
SPECIFICATIONS
RKE TRANSMITTER BATTERY . . . . . . . . . . . . . . 6
RKE TRANSMITTER RANGE . . . . . . . . . . . . . . . . 6
INTRODUCTION
The key fob transmi tter has three buttons to actu-
ate and program the Remote Keyl ess Entry (RKE)
system (Fi g. 1).
UNLOCK: Pressi ng the UNLOCK button once
wi l l unl ock the dri ver door and acti vate the i l l umi -
nated entry system and di sarm Vehi cl e Theft Secu-
ri ty System, i f equi pped. Pressi ng the UNLOCK
button twi ce wi thi n fi ve seconds wi l l unl ock al l doors
and acti vate the i l l umi nated entry system.
LOCK: Pressi ng the LOCK button l ocks al l
doors and sounds horn (chi rp) and arm the Vehi cl e
Theft Securi ty System. The chi rp veri fi es the door
l ock operati on.
PANI C: Pressi ng the PANI C button sounds the
horns at hal f second i nterval s, fl ashes the exteri or
l amps, and turns ON the i nteri or l amps. The pani c
al arm wi l l remai n on for three mi nutes, or unti l the
PANI C button i s actuated agai n or the i gni ti on
swi tch i s turned to the RUN posi ti on.
The Remote Keyl ess Entry Modul e i s capabl e of
retai ni ng the transmi tter Vehi cl e Access Code(s)
(VAC) i n i ts memory even after vehi cl e power has
been i nterrupted.
The RKE system acti vates the opti onal memory
seat and mi rror system, i f equi pped. Two pri mary
key fob transmi tters can be programmed to actuate
memory seat and mi rror setti ng 1 or 2. Two addi -
ti onal key fob transmi tters can be added, but they
wi l l not be abl e to operate the memory seat and mi r-
ror system. Refer to Group 8R, Power Seats and
Group 8T, Power Mi rrors for memory system i nfor-
mati on.
VEHICLE ACCESS CODE (VAC) PROGRAMMING
The RKE modul e i s capabl e of retai ni ng up to four
di fferent Vehi cl e Access Codes. Whenever the vehi cl e
battery power i s i nterrupted the RKE Modul e wi l l
retai n al l vehi cl e access codes i n i ts memory. When
repl aci ng or addi ng a key fob transmi tter (maxi mum
4) a functi onal key fob transmi tter i s requi red to pro-
gram the RKE Modul e to accept the new Vehi cl e
Access Code. I f a functi onal key fob transmi tter i s
not avai l abl e, a scan tool (DRB) can be used to pro-
gram the RKE Modul e. Refer to the proper Body
Di agnosti c Procedures manual for Vehi cl e Access
Code programmi ng procedures usi ng a scan tool .
RKE DIAGNOSTICS
i nformati on and component l ocati ons. Refer to the
proper Body Di agnosti c Procedures manual for test-
i ng the Remote Keyl ess Entry system usi ng a scan
tool (DRB). Al so refer to other i nterrel ated systems
groups wi thi n thi s manual :
Group 8Q, Vehi cl e Theft Securi ty System
Group 8R, Power Seats
Group 8T, Power Mi rrors
Fig. 1 Key Fob Transmitter
SERVICE PROCEDURES
HORN CHIRP DISABLE OR ENABLE
The horn chi rp can be DI SABLED or ENABLED
usi ng the fol l owi ng procedure.
To DI SABLE (cancel l i ng) the horn chi rp feature,
press and hol d the transmi tter LOCK button for a
mi ni mum four seconds. Whi l e pressi ng LOCK button
i n, press the UNLOCK button. The horn chi rp fea-
ture wi l l not functi on unti l the above procedure i s
repeated. To ENABLE (rei nstate) the horn chi rp fea-
ture, use any one of the four key fob transmi tters
and reverse the above procedures. I t wi l l ENABLE
the horn chi rp feature for al l transmi tters.
RKE MODULE
REMOVAL
Group 8E, I nstrument Panel and Gauges for proper
procedures.
(2) Remove screws hol di ng RKE modul e to i nstru-
ment panel .
(3) Di sconnect wi re connector from RKE modul e
(Fi g. 2).
(4) Remove the RKE modul e.
INSTALLATION
ADJ USTMENTS
PROGRAMMING RKE MODULE
(1) Usi ng a functi onal key fob transmi tter, unl ock
the vehi cl e and di sarm the Vehi cl e Theft Securi ty
System.
(2) I nsert i gni ti on key i nto the i gni ti on swi tch.
(3) Turn the i gni ti on swi tch to RUN posi ti on wi th-
out starti ng engi ne.
(4) Usi ng a functi onal key fob transmi tter, press
and hol d the UNLOCK button for a mi ni mum four
seconds (maxi mum ten seconds).
(5) Whi l e hol di ng UNLOCK button, and before ten
seconds passes, press and rel ease the PANI C button.
A si ngl e chi me wi l l sound to veri fy that the RKE
modul e i s set to recei ve the new Vehi cl e Access
Code(s).
(6) Wi thi n 30 seconds of the chi me, press any but-
ton on each new key fob transmi tter. After 30 sec-
onds or when i gni ti on swi tch i s turned OFF, the RKE
modul e wi l l end the programmi ng mode. A si ngl e
chi me wi l l sound to veri fy that the RKE modul e wi l l
no l onger recei ve addi ti onal Vehi cl e Access Code(s).
(7) When Vehi cl e Access Code(s) programmi ng i s
compl ete, turn I gni ti on Swi tch to the OFF posi ti on
and veri fy RKE system operati on usi ng each key fob.
NOTE: Only the primary (first two) key fob transmit-
ters will operate the memory seat and mirror sys-
tems. If a primary key fob is being replaced, the
memory seat and mirror module will require pro-
gramming. Refer to Group 8R, Power Seats for
proper (data link) programming procedure.
SPECIFICATIONS
RKE TRANSMITTER BATTERY
The batteri es can be removed wi thout speci al tool s
and are readi l y avai l abl e at l ocal retai l stores. The
recommended battery i s Duracel l DL 2016 or equi va-
l ent. Battery l i fe i s about one to two years.
CAUTION: Do not touch the battery terminals or
handle the batteries any more than necessary.
Hands must be clean and dry.
RKE TRANSMITTER RANGE
Normal operati on range i s up to about a di stance
of 7 meters (23 ft.) of the vehi cl e. Range may be bet-
ter or worse dependi ng on the envi ronment around
the vehi cl e. Cl oseness to a radi o frequency transmi t-
ter such as a radi o stati on tower may degrade oper-
ati onal range, whi l e range i n an open fi el d wi l l be
enhanced.
Fig. 2 RKE Module
VEHICLE THEFT SECURITY SYSTEM
CONTENTS
page page
GENERAL INFORMATION
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . 1
ARMING PROCEDURE . . . . . . . . . . . . . . . . . . . . 1
TIME-OUT PERIOD . . . . . . . . . . . . . . . . . . . . . . . 2
TRIGGERING THE VTSS . . . . . . . . . . . . . . . . . . . 2
BODY CONTROL MODULE . . . . . . . . . . . . . . . . . 2
DOOR LOCK CYLINDER SWITCH . . . . . . . . . . . . 2
FRONT DOOR AJ AR (VTSS TRIGGER)
SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
HOOD AJ AR (VTSS TRIGGER) SWITCH . . . . . . 3
LIFTGATE AJ AR (VTSS TRIGGER) SWITCH . . . . 3
LIFTGATE LOCK CYLINDER SWITCH . . . . . . . . . 3
SLIDING DOOR AJ AR (VTSS TRIGGER)
SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
GENERAL INFORMATION
INTRODUCTION
Vehi cl es equi pped wi th the Vehi cl e Theft Securi ty
System (VTSS) system, the doors, l i ftgate, hood and
i gni ti on ci rcui t are moni tored by the Body Control
Modul e (BCM) when the system i s armed. The VTSS
wi l l prevent the engi ne from starti ng unti l the BCM
recei ves a di sarm si gnal . I f the VTSS i s tri ggered,
the horn wi l l pul se, headl amps/marker l amps wi l l
fl ash, and the VTSS warni ng l amp wi l l fl ash. I f BCM
determi nes the threat to be fal se and the VTSS i s not
tri ggered agai n, the system wi l l shut down and
rearm i tsel f after three mi nutes. The VTSS moni tor-
i ng porti on of the system i s spl i t i nto two secti ons.
The engi ne compartment secti on and the passenger
compartment secti on. I f a mal functi on occurs i n the
engi ne compartment secti on, the passenger compart-
ment secti on woul d sti l l arm and functi on normal l y.
I f an el ectri cal mal functi on occurs i n ei ther secti on of
the system a Di agnosti c Troubl e Code (DTC) woul d
be stored the BCM memory to ai d system repai r.
DTCs can be retri eved usi ng scan tool (DRB)
attached to the di agnosti c connector above the accel -
erator pedal .
ENABLING
To i ni ti al i ze the VTSS feature the operator must,
wi th the engi ne compartment hood open, cycl e the
key i n the l i ftgate key cyl i nder to the unl ock posi ti on
gi vi ng the BCM a di sarm si gnal . At thi s ti me the
vi sual al arm outputs the headl amps and marker
l amps wi l l functi on. However the audi o al arm output
the horn and engi ne di sabl e porti on of the VTSS wi l l
not functi on unti l there has been twenty consecuti ve
engi ne run cycl es. When thi s has occurred the total
VTSS wi l l functi on.
I f duri ng al arm bei ng set the BCM recei ves a
request from the RKE modul e to enter PANI C mode
the BCM wi l l cancel the al arm, return VTSS armed
state and then perform the RKE PANI C feature.
ARMING PROCEDURE
METHOD-A
(1) Wi th the key removed from the i gni ti on l ock
and any door open, actuate one of the fol l owi ng:
Power door l ock button to LOCK,
Key fob LOCK button
Door l ock key cyl i nder to l ocked posi ti on.
(2) Cl ose al l opened doors.
(3) After the l ast door i s cl osed, an armi ng ti me-
out peri od of si xteen seconds wi l l start, then the
VTSS wi l l become armed.
METHOD-B
Actuati ng the key fob transmi tter LOCK button,
key l ocki ng the front doors or l i ftgate wi th the doors
cl osed and the i gni ti on l ocked wi l l begi n the armi ng
ti me-out peri od. I f method-A, 16 second ti me-out
sequence was i n process when method-B was actu-
ated, the 16 second ti me-out wi l l restart from the
ti me of the second actuati on.
I f the securi ty l amp does not i l l umi nate at al l upon
fi nal door cl osure, i t i ndi cates that the system i s not
armi ng.
The current VTSS status armed or di sarmed shal l
be mai ntai ned i n memory to prevent battery di scon-
nects from di sarmi ng the system.
NS VEHICLE THEFT SECURITY SYSTEM 8Q - 1
TIME-OUT PERIOD
The VTSS requi res 16 consecuti ve seconds to ti me-
out and arm the al arm. I f a door i s key unl ocked, key
fob unl ocked. or the i gni ti on i s swi tched ON, the
VTSS wi l l cancel out. To reset the VTSS, perform
methods A or B.
TRIGGERING THE VTSS
After the VTSS i s armed, fol l owi ng acti ons wi l l
tri gger the al arm:
Openi ng any door.
Openi ng the hood
Turni ng the i gni ti on to the ON or unl ock posi -
ti on.
The i gni ti on swi tch can be turned to the acces-
sory posi ti on wi thout tri ggeri ng al arm system.
i nformati on and component l ocati ons. Usi ng a scan
tool (DRB). Refer to the proper Body Di agnosti c Pro-
cedures manual for test procedures.
BODY CONTROL MODULE
REMOVAL
(1) Di sconnect the battery negati ve cabl e.
(2) Remove the l ower steeri ng col umn cover and
the knee bl ocker rei nforcement.
(3) Di sconnect the two wi re connectors from the
bottom of the Body Control Modul e (BCM) (Fi g. 1).
(4) Remove the bol ts hol di ng the Juncti on Bl ock to
the dash panel mounti ng bracket.
(5) Remove the Juncti on Bl ock from the mounti ng
bracket.
(6) Remove the screws hol di ng BCM to Juncti on
Bl ock.
(7) Sl i de the BCM downward to di sengage gui de
studs on Juncti on Bl ock from the channel s on the
(8) Remove the BCM from Juncti on Bl ock.
INSTALLATION
DOOR LOCK CYLINDER SWITCH
REMOVAL
(1) Remove the door tri m and water shi el d.
(2) Cl ose the door wi ndow.
(3) Di sconnect the door l ock cyl i nder swi tch wi re
connector from the door harness and wi ri ng cl i p from
the i mpact beam.
(4) Remove the outer handl e from the door.
(5) Di sengage the l ock tab hol di ng swi tch to the
back of the l ock cyl i nder (Fi g. 2).
(6) Remove the swi tch from the door handl e.
INSTALLATION
FRONT DOOR AJAR (VTSS TRIGGER) SWITCH
REMOVAL
(1) Open the front door.
(2) Remove the screw hol di ng the door ajar swi tch
to the door B-pi l l ar (Fi g. 3).
(3) Remove the door ajar swi tch from the B-pi l l ar.
Fig. 1 Body Control Module
Fig. 2 Door Lock Cylinder Switch
8Q - 2 VEHICLE THEFT SECURITY SYSTEM NS
the ajar swi tch and remove the swi tch.
INSTALLATION
HOOD AJAR (VTSS TRIGGER) SWITCH
REMOVAL
(1) Rel ease the hood l atch and open the hood.
(2) Usi ng a smal l fl at bl ade screws dri ver, pry tri g-
ger swi tch from top of the radi ator cl osure panel .
(3) Di sconnect the tri gger swi tch from the wi re
connector and remove the swi tch (Fi g. 4).
INSTALLATION
LIFTGATE AJAR (VTSS TRIGGER) SWITCH
REMOVAL
(1) Remove the l i ftgate l atch from the vehi cl e.
Refer to group 23, Body for proper procedures.
(2) Di sconnect the wi re connector from the l i ftgate
ajar swi tch.
(3) Remove the screw hol di ng the ajar swi tch to
the l i ftgate l atch and remove the swi tch (Fi g. 5).
INSTALLATION
For i nstal l ati on, Reverse the above procedure.
LIFTGATE LOCK CYLINDER SWITCH
REMOVAL
(1) Remove the i nner tri m panel from the l i ftgate.
Refer to Group 23, Body for proper procedure.
(2) Di sconnect the door l ock cyl i nder swi tch wi re
connector from the l i ftgate harness and cl i p from the
l i ftgate i nner panel .
(3) Remove the outsi de l atch rel ease handl e.
(4) Di sconnect the l ock tab hol di ng the swi tch to the
back of l ock cyl i nder and remove the swi tch (Fi g. 6).
INSTALLATION
Fig. 3 Front Door Ajar Switch
Fig. 4 Hood Ajar Switch
Fig. 5 Liftgate Ajar switch
Fig. 6 Liftgate Lock Cylinder Switch
NS VEHICLE THEFT SECURITY SYSTEM 8Q - 3
SLIDING DOOR AJAR (VTSS TRIGGER) SWITCH
REMOVAL
(1) Rel ease the sl i di ng door l atch and al l ow back of
the door to pop open.
(2) Through openi ng at the rear edge of the sl i di ng
door on outsi de of the vehi cl e, pry door ajar swi tch
from quarter panel openi ng (Fi g. 7).
the ajar swi tch.
(4) Remove the sl i di ng door ajar swi tch.
INSTALLATION
Fig. 7 Sliding Door Ajar Switch
8Q - 4 VEHICLE THEFT SECURITY SYSTEM NS
VEHICLE THEFT/SECURITY SYSTEMS
CONTENTS
page page
GENERAL INFORMATION
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . 1
SMART KEY IMMOBILIZER SYSTEM . . . . . . . 1
SMART KEY IMMOBILIZER MODULE . . . . . . . 1
SMART KEY IMMOBILIZER SYSTEM
INDICATOR LAMP . . . . . . . . . . . . . . . . . . . . . 3
SMART KEY IMMOBILIZER TRANSPONDER . 2
SMART KEY IMMOBILIZER SYSTEM . . . . . . . 3
SERVICE PROCEDURES
TRANSPONDER PROGRAMMING . . . . . . . . . 4
SMART KEY IMMOBILIZER MODULE . . . . . . . 4
GENERAL INFORMATION
INTRODUCTION
The Smart Key I mmobi l i zer System (SKI S) i s
avai l abl e factory-i nstal l ed opti onal equi pment for thi s
model . Fol l owi ng are some general descri pti ons of the
features and components of the SKI S. Refer to the
vehi cl e owners manual for more i nformati on on the
use and operati on of the SKI S. Refer to 8W-30 - Fuel /
I gni ti on System i n Group 8W - Wi ri ng Di agrams for
compl ete ci rcui t descri pti ons and di agrams.
The Smart Key I mmobi l i zer System (SKI S) i s
desi gned to provi de passi ve protecti on agai nst unau-
thori zed vehi cl e use by preventi ng the engi ne from
operati ng whi l e the system i s armed. The pri mary
components of thi s system are the Smart Key I mmo-
bi l i zer Modul e (SKI M), the Smart Key transponder,
the SKI S i ndi cator l amp, and the Powertrai n Control
Modul e (PCM), for gasol i ne engi nes, and the Body
Control Modul e (BCM) for di esel engi nes.
The SKI M i s i nstal l ed on the steeri ng col umn near
the i gni ti on l ock cyl i nder. The transponder i s l ocated
under the mol ded rubber cap on the head of the i gni -
ti on key. The SKI S i ndi cator l amp i s l ocated i n the
The SKI S i ncl udes two val i d Smart Key transpon-
ders from the factory. I f the customer wi shes, addi -
ti onal non-coded bl ank Smart Keys are avai l abl e.
These bl ank keys can be cut to match a val i d i gni ti on
key, but the engi ne wi l l not start unl ess the key tran-
sponder i s al so programmed to the vehi cl e. The SKI S
wi l l recogni ze no more than ei ght val i d Smart Key
transponders at any one ti me.
The SKI S performs a sel f-test each ti me the i gni -
ti on swi tch i s turned to the On posi ti on, and wi l l
store Di agnosti c Troubl e Codes (DTCs) i f a system
mal functi on i s detected. The SKI S can be di agnosed,
and any stored DTC can be retri eved usi ng a DRB
scan tool as descri bed i n the proper Di agnosti c Pro-
cedures manual .
SMART KEY IMMOBILIZER MODULE
The Smart Key I mmobi l i zer Modul e (SKI M) con-
tai ns a Radi o Frequency (RF) transcei ver and a cen-
tral processi ng uni t, whi ch i ncl udes the Smart Key
I mmobi l i zer System (SKI S) program l ogi c. The SKI S
programmi ng enabl es the SKI M to program and
retai n i n memory the codes of at l east two, but no
more than ei ght el ectroni cal l y coded Smart Key tran-
sponders. The SKI S programmi ng al so enabl es the
SKI M to communi cate over the Chrysl er Col l i si on
Detecti on (CCD) data bus network wi th the Power-
trai n Control Modul e (PCM), the i nstrument cl uster
and/or the DRB scan tool .
The SKI M transmi ts and recei ves RF si gnal s
through a tuned antenna encl osed wi thi n a mol ded
pl asti c ri ng formati on that i s i ntegral to the SKI M
housi ng. When the SKI M i s properl y i nstal l ed on the
steeri ng col umn, the antenna ri ng i s ori ented around
the ci rcumference of the i gni ti on l ock cyl i nder hous-
i ng. Thi s antenna ri ng must be l ocated wi thi n ei ght
mi l l i meters (0.31 i nches) of the Smart Key i n order
to ensure proper RF communi cati on between the
SKI M and the Smart Key transponder.
For added system securi ty, each SKI M i s pro-
grammed wi th a uni que Secret Key code and a
securi ty code. The SKI M keeps the Secret Key code
i n memory and sends the code over the CCD data
bus to the PCM, whi ch al so keeps thi s code i n i ts
memory. The SKI M al so sends the Secret Key code
to each of the programmed Smart Key transponders.
The securi ty code i s used by the assembl y pl ant to
NS/GS VEHICLE THEFT/SECURITY SYSTEMS 8Q - 1
access the SKI S for i ni ti al i zati on, or by the deal er
techni ci an to access the system for servi ce. The
SKI M al so stores i n i ts memory the Vehi cl e I denti fi -
cati on Number (VI N), whi ch i t l earns through a CCD
data bus message from the PCM duri ng i ni ti al i za-
ti on.
The SKI M and the PCM both use software that
i ncl udes a rol l i ng code al gori thm strategy, whi ch
hel ps to reduce the possi bi l i ty of unauthori zed SKI S
di sarmi ng. The rol l i ng code al gori thm ensures secu-
ri ty by preventi ng an overri de of the SKI S through
the unauthori zed substi tuti on of the SKI M or the
PCM. However, the use of thi s strategy al so means
that repl acement of ei ther the SKI M or the PCM
uni ts wi l l requi re a system i ni ti al i zati on procedure to
restore system operati on.
When the i gni ti on swi tch i s turned to the On or
Start posi ti ons, the SKI M transmi ts an RF si gnal to
exci te the Smart Key transponder. The SKI M then
l i stens for a return RF si gnal from the transponder
of the Smart Key that i s i nserted i n the i gni ti on l ock
cyl i nder. I f the SKI M recei ves an RF si gnal wi th
val i d Secret Key and transponder i denti fi cati on
codes, the SKI M sends a val i d key message to the
PCM over the CCD data bus. I f the SKI M recei ves
an i nval i d RF si gnal or no response, i t sends i nval i d
key messages to the PCM. The PCM wi l l enabl e or
di sabl e engi ne operati on based upon the status of the
SKI M messages.
The SKI M al so sends messages to the i nstrument
cl uster over the CCD data bus network to control the
SKI S i ndi cator l amp. The SKI M sends messages to
the i nstrument cl uster to turn the l amp on for about
three seconds when the i gni ti on swi tch i s turned to
the On posi ti on as a bul b test. After compl eti on of
the bul b test, the SKI M sends bus messages to keep
the l amp off for a durati on of about one second. Then
the SKI M sends messages to turn the l amp on or off
based upon the resul ts of the SKI S sel f-tests. I f the
SKI S i ndi cator l amp comes on and stays on after the
bul b test, i t i ndi cates that the SKI M has detected a
system mal functi on and/or that the SKI S has become
i noperati ve.
I f the SKI M detects an i nval i d key when the i gni -
ti on swi tch i s turned to the On posi ti on, i t sends
messages to the i nstrument cl uster to fl ash the SKI S
i ndi cator l amp. The SKI M can al so send messages to
the i nstrument cl uster to fl ash the l amp and to gen-
erate a si ngl e audi bl e chi me tone.
For di agnosi s or i ni ti al i zati on of the SKI M and the
PCM, a DRB scan tool and the proper Di agnosti c
Procedures manual are requi red. The SKI M cannot
be repai red and, i f faul ty or damaged, the uni t must
be repl aced.
SMART KEY IMMOBILIZER TRANSPONDER
The Smart Key I mmobi l i zer System (SKI S) uses a
transponder that i s i ntegral to each of the two i gni -
ti on keys that are suppl i ed wi th the vehi cl e when i t
i s shi pped from the factory. The transponder chi p i s
i nsul ated wi thi n a nyl on mount i nserted i n the head
of the key, and i nvi si bl e beneath a mol ded rubber cap
(Fi g. 1).
Each Smart Key transponder has a uni que tran-
sponder i denti fi cati on code programmed i nto i t by the
manufacturer. The Smart Key I mmobi l i zer Modul e
(SKI M) has a uni que Secret Key code programmed
i nto i t by the manufacturer. When a Smart Key tran-
sponder i s programmed i nto the memory of the
SKI M, the SKI M l earns the transponder i denti fi ca-
ti on code from the transponder, and the transponder
l earns the Secret Key code from the SKI M. Each of
these codes i s stored wi thi n the transponder and i n
the nonvol ati l e memory of the SKI M. Therefore,
bl ank keys for the SKI S must be programmed by and
i nto the SKI M, i n addi ti on to bei ng cut to match the
mechani cal codi ng of the i gni ti on l ock cyl i nder. See
Smart Key I mmobi l i zer System Transponder Pro-
grammi ng i n thi s group for more i nformati on.
The Smart Key transponder i s wi thi n the range of
the SKI M transcei ver antenna ri ng when i t i s
i nserted i n the i gni ti on l ock cyl i nder. When the i gni -
ti on swi tch i s turned to the Start or On posi ti ons, the
SKI M transcei ver i ssues a Radi o Frequency (RF) si g-
nal that exci tes the transponder chi p. The transpon-
der chi p responds by i ssui ng an RF si gnal contai ni ng
i ts transponder i denti fi cati on code and the Secret
Key code. The SKI M transcei ver compares the tran-
sponder codes wi th the codes stored i n i ts memory to
Fig. 1 Smart Key Immobilizer Transponder
8Q - 2 VEHICLE THEFT/SECURITY SYSTEMS NS/GS
determi ne whether a val i d key i s i n the i gni ti on l ock
cyl i nder.
The Smart Key transponder cannot be repai red
and, i f faul ty or damaged, i t must be repl aced.
SMART KEY IMMOBILIZER SYSTEM INDICATOR
LAMP
The Smart Key I mmobi l i zer System (SKI S) i ndi ca-
tor l amp gi ves an i ndi cati on when the SKI S i s faul ty
or when the vehi cl e has been i mmobi l i zed due to the
use of an i nval i d i gni ti on key. The l amp i s control l ed
by the i nstrument cl uster ci rcui try based upon mes-
sages recei ved from the Smart Key I mmobi l i zer Mod-
ul e (SKI M) on the Chrysl er Col l i si on Detecti on (CCD)
data bus.
The SKI M sends messages to the i nstrument cl us-
ter to turn the l amp on for about three seconds when
the i gni ti on swi tch i s turned to the On posi ti on as a
bul b test. After compl eti on of the bul b test, the SKI M
sends bus messages to keep the l amp off for a dura-
ti on of about one second. Then the SKI M sends mes-
sages to the i nstrument cl uster ci rcui try to turn the
l amp on or off based upon the resul ts of the SKI S
sel f-tests. I f the SKI S i ndi cator l amp comes on and
stays on after the bul b test, i t i ndi cates that the
SKI M has detected a system mal functi on and/or that
the SKI S has become i noperati ve. I f the SKI M
detects an i nval i d key when the i gni ti on swi tch i s
turned to the On posi ti on, i t sends messages to the
i nstrument cl uster to fl ash the SKI S i ndi cator l amp.
The SKI M can al so send messages to the i nstru-
ment cl uster to fl ash the l amp and to generate a si n-
gl e audi bl e chi me tone. These functi ons serve as an
i ndi cati on to the customer that the SKI S has been
pl aced i n i ts Customer Learn programmi ng mode.
See Smart Key I mmobi l i zer System Transponder Pro-
grammi ng i n thi s group for more i nformati on on the
Customer Learn programmi ng mode.
The SKI S i ndi cator l amp uses a repl aceabl e i ncan-
descent bul b and bul b hol der on the i nstrument cl us-
ter el ectroni c ci rcui t board. Refer to Group 8E -
I nstrument Panel Systems for di agnosi s and servi ce
of a faul ty SKI S i ndi cator l amp. I f the SKI S i ndi cator
l amp comes on and stays on after the bul b test func-
ti on, di agnosi s of the SKI S shoul d be performed wi th
a DRB scan tool and the proper Di agnosti c Proce-
dures manual .
INJURY.
NOTE: The following tests may not prove conclu-
sive in the diagnosis of this system. The most reli-
able, efficient, and accurate means to diagnose the
Smart Key Immobilizer System involves the use of a
DRB scan tool. Refer to the proper Diagnostic Pro-
cedures manual for the procedures.
The Smart Key I mmobi l i zer System (SKI S) and the
Chrysl er Col l i si on Detecti on (CCD) data bus network
shoul d be di agnosed usi ng a DRB scan tool . The DRB
wi l l al l ow confi rmati on that the CCD data bus i s
functi onal , that the Smart Key I mmobi l i zer Modul e
(SKI M) i s pl aci ng the proper messages on the CCD
data bus, and that the Powertrai n Control Modul e
(PCM) and the i nstrument cl uster are recei vi ng the
CCD data bus messages. Refer to the proper Di ag-
nosti c Procedures manual for the procedures. Refer
to 8W-30 - Fuel /I gni ti on System i n Group 8W - Wi r-
i ng Di agrams for compl ete ci rcui t descri pti ons and
di agrams.
(1) Check the fuses i n the fusebl ock modul e. I f OK,
go to Step 2. I f not OK, repai r the shorted ci rcui t or
component as requi red and repl ace the faul ty fuse.
cabl e. Unpl ug the wi re harness connector at the
SKI M. Check for conti nui ty between the ground ci r-
cui t cavi ty of the SKI M wi re harness connector and a
good ground. There shoul d be conti nui ty. I f OK, go to
Step 3. I f not OK, repai r the open ci rcui t to ground
as requi red.
(3) Connect the battery negati ve cabl e. Check for
battery vol tage at the fused B(+) ci rcui t cavi ty of the
SKI M wi re harness connector. I f OK, go to Step 4. I f
not OK, repai r the open ci rcui t to the fuse i n the
fusebl ock modul e as requi red.
(4) Turn the i gni ti on swi tch to the On posi ti on.
Check for battery vol tage at the fused i gni ti on swi tch
output (run/start) ci rcui t cavi ty of the SKI M wi re
harness connector. I f OK, use a DRB scan tool and
the proper Di agnosti c Procedures manual to compl ete
the di agnosi s of the SKI S. I f not OK, repai r the open
ci rcui t to the fuse i n the fusebl ock modul e as
requi red.
SERVICE PROCEDURES
TRANSPONDER PROGRAMMING
Two programmed Smart Key transponders are
i ncl uded wi th the Smart Key I mmobi l i zer System
(SKI S) when i t i s shi pped from the factory. The
Smart Key I mmobi l i zer Modul e (SKI M) can be pro-
grammed to recogni ze up to si x addi ti onal transpon-
ders, for a total of ei ght Smart Keys. The fol l owi ng
Customer Learn programmi ng procedure for the
programmi ng of addi ti onal transponders requi res
access to at l east two of the val i d Smart Keys. I f two
val i d Smart Keys are not avai l abl e, Smart Key pro-
grammi ng wi l l requi re the use of a DRB scan tool
and the proper Di agnosti c Procedures manual .
PROGRAMMING THE SKIM MODULE WITH
THE DRBIII
(1) Turn the i gni ti on on. Transmi ssi on must be i n
park or neutral . Al arm set l amp wi l l fl ash.
(2) Use the DRBI I I and sel ect SKI M under the
MI SCELLANEOUS menu.
(3) Sel ect PROGRAM PI N and enter the cus-
tomer 4di gi t PI N number.
(4) Sel ect UPDATE VI N. The SKI M modul e wi l l
l earn the VI N from the PCM i n gasol i ne engi ne vehi -
cl es, and from the BCM i n di esel engi ne vehi cl es.
(5) Sel ect COUNTRY CODE and enter the cor-
rect country.
(6) Sel ect PROGRAM NEW EMS. The SKI M
modul e wi l l send the secret key data to the PCM.
(7) Program i gni ti on keys to the SKI M modul e.
PROGRAMMING IGNITION KEYS WITH THE
DRBIII
(1) Turn i gni ti on on. Transmi ssi on must be i n park
or neutral . Al arm set l amp wi l l fl ash.
(2) Use the DRBI I I and sel ect SKI M under the
MI SCELLANEOUS menu.
(3) Sel ect LEARN NEW KEY. Al arm Set l amp
wi l l begi n fl ashi ng.
NOTE: The PIN must be re-entered each time an
additional key is learned.
(4) I nsert key i nto i gni ti on swi tch. Once the key
has been l earned, the Al arm Set l amp wi l l turn off.
SMART KEY IMMOBILIZER MODULE
INJURY.
cabl e.
(2) Remove the knee bl ocker from the i nstrument
panel . See Knee Bl ocker i n Group 8E - I nstrument
Panel Systems for the procedures.
(3) Remove the three screws that secure the l ower
steeri ng col umn shroud to the upper shroud.
(4) I f the vehi cl e i s so equi pped, move the ti l t
steeri ng col umn to the ful l y l owered posi ti on.
(5) I f the vehi cl e i s so equi pped, l oosen the two
nuts that secure the non-ti l t steeri ng col umn upper
mounti ng bracket to the dash panel steeri ng col umn
support bracket studs. Lower the col umn far enough
to remove the upper steeri ng col umn shroud.
(6) Remove both the upper and l ower shrouds from
the steeri ng col umn.
Fig. 2 Steering Column Shrouds Remove/Install
8Q - 4 VEHICLE THEFT/SECURITY SYSTEMS NS/GS
(7) Unpl ug the wi re harness connector from the
SKI M receptacl e.
(8) Remove the screw securi ng the SKI M modul e
to the steeri ng col umn.
(9) Rel ease the cl i p hol di ng the SKI M antenna to
the i gni ti on l ock housi ng on the steeri ng col umn.
(10) Remove the SKI M from the vehi cl e.
(11) Reverse the removal procedures to i nstal l .
Ti ghten the non-ti l t steeri ng col umn mounti ng nuts
to 22 Nm (200 i n. l bs.) and the steeri ng col umn
shroud mounti ng screws to 2 Nm (18 i n. l bs.).
(12) I f the SKI M i s repl aced wi th a new uni t, a
DRB scan tool and the proper Di agnosti c Procedures
manual MUST be used to i ni ti al i ze the new SKI M
and to program at l east two Smart Key transponders.
Fig. 3 Smart Key Immobilizer Module Remove/Install
POWER WINDOWS
CONTENTS
page page
GENERAL INFORMATION
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . 1
POWER VENT WINDOW MOTOR TEST . . . . . . . 1
POWER WINDOW AND VENT SWITCH TEST . . 2
POWER WINDOW MOTOR TEST . . . . . . . . . . . . 2
WIRING VOLTAGE TEST . . . . . . . . . . . . . . . . . . . 3
POWER VENT WINDOW MOTOR . . . . . . . . . . . . 3
POWER WINDOW MOTOR . . . . . . . . . . . . . . . . . 3
POWER WINDOW SWITCH . . . . . . . . . . . . . . . . 3
GENERAL INFORMATION
INTRODUCTION
Front door wi ndow l i ft motors use permanent type
magnets. The B+ and ground appl i ed at the motor
termi nal pi ns wi l l cause the motor to rotate i n one
di recti on. Reversi ng current through the motor ter-
mi nal s wi l l cause the motor to rotate i n the opposi te
di recti on.
The power wi ndow motors ground through the
master swi tch i n the dri ver door (Fi g. 1) by a bl ack
wi re attached to the l eft cowl panel . Refer to Group
8W, Wi ri ng Di agrams from ci rcui t i nformati on and
component l ocati ons.
The power rear vent wi ndows, i f equi pped, are
operated by swi tches mounted i n the dri ver door
swi tch bezel . A separate swi tch i s used for each wi n-
dow. Permanent magnet type motors connected to a
crank system are used to open and cl ose the rear
vent wi ndows. A battery posi ti ve and negati ve con-
necti on to ei ther of the two motor termi nal s wi l l
cause the motor to rotate i n one di recti on. Reversi ng
current through these same two connecti ons wi l l
cause the motor to rotate i n the opposi te di recti on.
Refer to Group 8W, Wi ri ng Di agrams for ci rcui t i nfor-
mati on and component l ocati ons.
POWER VENT WINDOW MOTOR TEST
I f the power vent wi ndow motor i s recei vi ng proper
current and ground and does not operate proceed
wi th motor test. Refer to Group 8W, Wi ri ng Di agrams
for ci rcui t i nformati on and component l ocati ons.
(1) Remove D-pi l l ar tri m panel necessary to gai n
access to power vent wi ndow motor wi re connector,
refer to Group 23, Body for proper procedures.
(2) Di sconnect power vent wi ndow motor wi re con-
nector from body harness.
(3) Usi ng two jumper wi res, connect one to a bat-
tery (+) source and the other to a good ground (-).
(4) Connect the Negati ve (-) jumper probe to one of
the motor connector termi nal s.
(5) Momentari l y touch the Posi ti ve (+) jumper
probe to the other motor connector termi nal .
When posi ti ve probe i s connected the motor shoul d
rotate i n one di recti on to ei ther move wi ndow open or
cl osed. I f wi ndow i s al l the way open or cl osed the
motor wi l l grunt and the crank system wi l l fl ex when
actuated i n that one di recti on.
Reverse jumper probes at the motor connector ter-
mi nal s and wi ndow shoul d now move i n opposi te
di recti on. I f wi ndow does not move or grunt, repl ace
the motor.
I f wi ndow moved compl etel y open or cl osed, reverse
the jumper probes and cycl e wi ndow to the opposi te
posi ti on to veri fy ful l operati on.
I f motor grunts and does not move, veri fy that
crank system i s not bi ndi ng.
Fig. 1 Power Window Master Switch
NS POWER WINDOWS 8S - 1
POWER WINDOW AND VENT SWITCH TEST
(1) Remove the dri ver or passenger door power
wi ndow swi tch and bezel assembl y from door tri m
panel . Refer to group 23, Body for proper procedures.
(2) Usi ng an ohmmeter, Test dri ver door swi tch for
conti nui ty as descri bed i n (Fi g. 2).
* MUST TEST WI TH B+ ON PI N 9 AND
GROUND ON PI N 13 FOR CONTI NUI TY
BETWEEN PI NS 11 AND 6
(3) Test passenger door swi tch for conti nui ty as
descri bed i n (Fi g. 3).
(4) I f the resul ts are not OK, repl ace the swi tch.
The dri ver door power wi ndow swi tch has a Auto-
Down feature. The swi tch i s equi pped wi th two
detent posi ti ons when actuati ng the power wi ndow
OPEN. The fi rst detent posi ti on al l ows the wi ndow to
rol l down and stop when the swi tch i s rel eased. The
second detent posi ti on actuates an i ntegral express
rol l down rel ay that rol l s the wi ndow down after the
swi tch i s rel eased. When the express down rel ay
senses an amperage spi ke (motor pushi ng agai nst
down stop) i n the feed ci rcui t, current i s turned off to
the motor. The AUTO feature can be cancel l ed by
actuati ng the swi tch UP or DOWN whi l e wi ndow i s
i n moti on. Fai l ure of the el ectroni c swi tch to detect
an amperage spi ke wi l l cause the swi tch to di scon-
nect after approxi matel y 11 seconds.
POWER WINDOW MOTOR TEST
I f the power wi ndow motor i s recei vi ng proper cur-
rent and ground and does not operate proceed wi th
motor test. Refer to Group 8W, Wi ri ng Di agrams for
ci rcui t i nformati on and component l ocati ons.
(1) Remove front door tri m panel and water shi el d
as necessary to gai n access to power wi ndow motor
wi re connector, refer to Group 23, Body for proper
procedures.
(2) Di sconnect power wi ndow motor wi re connector
from door harness.
(3) Usi ng two jumper wi res, connect one to a bat-
tery (+) source and the other to a good ground (-).
(4) Connect the Negati ve (-) jumper probe to one of
the motor connector termi nal s.
(5) Momentari l y touch the Posi ti ve (+) jumper
probe to the other motor connector termi nal .
When posi ti ve probe i s connected the motor shoul d
rotate i n one di recti on to ei ther move wi ndow up or
down. I f wi ndow i s al l the way up or down the motor
wi l l grunt and the i nner door panel wi l l fl ex when
actuated i n that one di recti on.
(6) Reverse jumper probes at the motor connector
termi nal s and wi ndow shoul d now move i n opposi te
di recti on. I f wi ndow does not move or grunt, repl ace
the motor.
I f wi ndow moved compl etel y up or down, reverse
the jumper probes and cycl e wi ndow to the opposi te
posi ti on to veri fy ful l operati on.
Fig. 2 Driver Side Power Window Switch Connector
DRIVER DOOR POWER WINDOW SWITCH
TEST
SWITCH POSITION
CONTINUITY
BETWEEN
OFF 13 and 1
13 and 2
13 and 3
13 and 4
13 and 5
13 and 6
13 and 7
13 and 8
UP DRIVER 11 and 8
*DOWN DRIVER 11 and 6
*X DOWN DRIVER 11and 6
UP PASSENGER 9 and 4
DOWN PASSENGER 9 and 2
LEFT VENT OPEN 11 and 7
LEFT VENT CLOSE 9 and 3
RIGHT VENT OPEN 9 and 1
RIGHT VENT CLOSE 11 and 5
Fig. 3 Passenger Door Power Window Switch
8S - 2 POWER WINDOWS NS
I f motor grunts and does not move, veri fy that reg-
ul ator i s not bi ndi ng.
WIRING VOLTAGE TEST
The fol l owi ng wi ri ng test determi nes whether or
not vol tage i s conti nuous through the body harness
to swi tch.
(1) Remove the master power wi ndow swi tch and
bezel assembl y from the dri ver door. Refer to Group
23, Body for proper procedures.
wi ndow swi tch.
(3) Swi tch i gni ti on ON posi ti on.
(4) Connect the cl i p end of a 12 vol t test l i ght to
Pi n 13 i n door harness connector at the wi ndow
swi tch. Touch the test l i ght probe to Pi n 9 and then
to Pi n 11.
I f the test l i ght i l l umi nates, the wi ri ng ci rcui t
between the battery and swi tch i s OK.
I f l i ght does not i l l umi nate, check the 40 amp
fuse i n the Power Di stri buti on Center or for a broken
wi re.
The power wi ndow motors are protected wi th
Posi ti ve Temperature Coeffi ci ent (PTC) devi ce that
prevents motor burn out. Check Juncti on Bl ock.
i nformati on and component l ocati ons.
POWER VENT WINDOW MOTOR
REMOVAL
(2) Remove D-pi l l ar tri m panel .
(3) Di sconnect wi re connector from power vent
motor.
(4) Remove nut hol di ng crank to vent gl ass.
(5) Remove bol ts hol di ng power vent motor to
D-pi l l ar (Fi g. 4).
(6) Remove power vent motor.
(7) Pul l the crank system from the motor.
INSTALLATION
Before i nstal l i ng crank, cycl e repl acement motor to
the open posi ti on. I nstal l crank hi nge i n extended
posi ti on to the motor and for i nstal l ati on, reverse the
above procedures.
POWER WINDOW SWITCH
To remove power wi ndow swi tches refer to Group
23, Body for proper procedures.
POWER WINDOW MOTOR
WARNING: DO NOT HAVE ANY HANDS OR FIN-
GERS IN SECTOR GEAR AREA WHERE THEY CAN
BE PINCHED BY SMALL MOVEMENTS OF REGULA-
TOR LINKAGE.
REMOVAL
(1) Tape the wi ndow i n i ts exi sti ng posi ti on to
remove i ts wei ght from the regul ator system.
(2) Cut and remove the ti e wrap at the wi ndow
motor. I ts no l onger requi red.
(3) Di sconnect wi ndow motor wi re connector from
door harness.
(4) Remove screws and nuts hol di ng wi ndow motor
to the i nner panel .
(5) Remove the motor from the door i nner panel ,
l et i t hang from the cabl es.
(6) Wi th the cabl es sti l l attached to the fai l ed
motor, I nstal l the repl acement motor to the door
i nner panel . Ti ghten down the screws and nuts to 3.4
to 4.5 Nm ( 30 to 40 i n. l bs.) of torque.
(7) Separate the fai l ed motor from regul ator by:
Removi ng the drum cover pl ate.
Li ft the cabl e gui de off the motor, the drum wi th
cabl es, wi l l be l i fted off si mul taneousl y (Fi g. 5).
CAUTION: Do not allow the drum to separate from
the cable guide, by dropping drum or letting the
cables unwind.
INSTALLATION
(1) I nstal l the cabl e gui de and drum i nto the
repl acement motor.
Fig. 4 Vent Window Motor
NS POWER WINDOWS 8S - 3
CAUTION: The drum may require a slight rotation
to install onto the motor drive shaft. Rotate the
drum with the use of needle nose pliers or a similar
tool. If, the drum does not align with the motor
shaft by a slight rotation, then, the glass should be
lowered a small amount approximately 1 to 2
inches. The drum will rotate when the glass is low-
ered. Lowering the glass will require assistance of a
second person.
(2) i nstal l the repl acement cover pl ate onto the
repl acement motor. Cri mp toy tabs.
(3) Connect the wi ri ng harness to the wi ndow
motor connector.
(4) Remove the tape hol di ng the wi ndow i n pl ace
and test wi ndow operati on.
Fig. 5 Power Window Motor Removal
8S - 4 POWER WINDOWS NS
POWER SEATS
CONTENTS
page page
MEMORY SEAT AND MIRROR SYSTEM . . . . . . . 3 POWER SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
POWER SEATS
INDEX
page page
GENERAL INFORMATION
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . 1
POWER SEAT SWITCH . . . . . . . . . . . . . . . . . . . . 1
SEAT MOTORS . . . . . . . . . . . . . . . . . . . . . . . . . . 1
GENERAL INFORMATION
INTRODUCTION
Power seats can be adjusted i n ei ght di recti ons; up,
down, forward, back, ti l t forward, or ti l t rearward.
Four reversi bl e motors and a transmi ssi on l ocated on
the seat tracks provi de the vari ous seat movements.
The el ectri cal ci rcui t i s protected by a 40 amp fuse i n
the Power Di stri buti on Center (PDC) and a 30 amp
ci rcui t breaker l ocated i n the wi re harness under the
dri vers seat.
Before testi ng the seat functi ons, veri fy that the
battery i s ful l y charged and the termi nal s cl eaned
and ti ghtened to ensure proper connecti ons. I f the
battery i s not ful l y charged, refer to Group 8A Bat-
tery for proper testi ng procedures.
The fol l owi ng test wi l l determi ne i f the ci rcui t i s
compl ete through the body harness to the swi tch:
Usi ng a vol tmeter, veri fy the condi ti on of the power
seat ci rcui t breaker l ocated under the dri vers seat.
The ci rcui t breaker al so protects the passenger si de
power seat track ci rcui t. Check both si des of the ci r-
cui t breaker connector for vol tage, on the wi re si de.
I f not OK repl ace ci rcui t breaker.
I f battery vol tage i s detected on both si des of the
ci rcui t breaker. Refer to Seat Motor i n the Di agnosti c
and Testi ng i n thi s secti on.
I f seat motors test OK, refer to the Seat Swi tch
i n the Di agnosti c and Testi ng i n thi s secti on.
Refer to Group 8W Wi ri ng Di agrams for wi re
ci rcui t i nformati on.
SEAT MOTORS
(1) Remove power seat swi tch from seat. Refer to
Group 23 Body for procedures.
(2) Di sconnect wi re connector.
(3) Usi ng a vol tmeter check for battery vol tage at
Pi n 5. Usi ng an ohmmeter, check Pi n 1 for ground.
(4) To test the seat motors, refer to (Fi g. 1) and
veri fy proper seat responses. Usi ng two jumper
wi res, connect one to a battery suppl y and the other
to a ground. Connect the other ends to the seat wi re
harness connector as descri bed i n (Fi g. 1). I f any
motor fai l s to operate, check wi re connectors to the
motor. I f not OK, repai r as necessary. I f OK, repl ace
seat motor/track assembl y.
POWER SEAT SWITCH
(1) Remove power seat swi tch from seat. Refer to
Group 23 Body for procedures.
(2) Usi ng an ohmmeter, perform the swi tch conti -
nui ty tests i n (Fi g. 2). I f there i s no conti nui ty at any
of the swi tch posi ti ons, repl ace swi tch.
NS POWER SEATS 8R - 1
Fig. 1 Seat Motor Test
Fig. 2 Power Seat Switch Test
8R - 2 POWER SEATS NS
MEMORY SEAT AND MIRROR SYSTEM
INDEX
page page
GENERAL INFORMATION
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . 3
MEMORY SELECTOR SWITCHES . . . . . . . . . . . . 3
POSITION SENSING SEAT AND RECLINER
POTENTIOMETERS . . . . . . . . . . . . . . . . . . . . . 4
POWER SIDE VIEW MIRROR POSITION
SENSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SEAT AND RECLINER SWITCHES . . . . . . . . . . . . 4
CIRCUIT DESCRIPTION . . . . . . . . . . . . . . . . . . . . 7
DIAGNOSTIC MODE . . . . . . . . . . . . . . . . . . . . . . 5
MEMORY SELECTOR SWITCHES . . . . . . . . . . . . 4
SEAT AND RECLINER POSITION SENSING . . . . 9
SIDE VIEW MIRROR SWITCH STUCK . . . . . . . . . 4
SERVICE PROCEDURES
REMOTE KEYLESS ENTRY (RKE) DATA LINK . . . 9
MEMORY SWITCHES . . . . . . . . . . . . . . . . . . . . . 10
SEAT TRACK ASSEMBLY . . . . . . . . . . . . . . . . . . 10
GENERAL INFORMATION
INTRODUCTION
Memory Seat and Mi rrors system i s avai l abl e onl y
on Town and Country (Luxury Cl ass) vehi cl es.
i nformati on and component l ocati ons. Refer to the
proper Body Di agnosti c Procedures manual for addi -
ti onal di agnosti c i nformati on.
The Memory Seat/Mi rror Modul e (MSM Modul e) i s
mounted under the dri vers seat, on the i nboard
upper track wi th Torx head screws. The MSM Mod-
ul e provi des the dri ver wi th an adjustabl e seat,
recl i ner, and power si de vi ew mi rror posi ti oni ng con-
trol l er that remembers stored posi ti ons and wi l l
recal l those posi ti ons on command.
The Memory Seat/Mi rror Modul e reads al l seat and
recl i ner swi tch i nputs and operates the seat and
recl i ner motors i n response to swi tch actuati on. The
MSM Modul e moni tors posi ti on sensi ng potenti ome-
ters (mounted on the motors) for seat and recl i ner
posi ti oni ng.
The MSM Modul e operates the power si de vi ew
mi rror motors through sol i d state dri vers (el ectroni c
swi tches) i n the recal l mode onl y, and fol l ows the
gl ass face posi ti on by means of rheostats bui l t i nto
the motor pack assembl y of the mi rrors. Normal el ec-
tri cal operati on of the mi rrors i s accompl i shed by
actuati on of the power mi rror swi tch.
The Memory Seat/Mi rror Modul e moni tors the mem-
ory swi tches and has the capabi l i ty to store desi red
posi ti ons i n non-vol ati l e memory i n response to a val i d
i nput sequence. Refer to Memory Sel ector Swi tches (1,
2, and S) and Remote Keyl ess Entry (RKE) Data Li nk.
The memory seat/mi rror modul e al so can acti vate the
previ ousl y descri bed motors i n response to a recal l
request from an i ndi vi dual memory swi tch.
The Memory Seat/Mi rror Modul e moni tors a data
l i nk between the RKE recei ver and the Body Control
Modul e (BCM) and wi l l respond to stored i nformati on
or modi fy stored i nformati on when requested by a
val i d data stream.
The Memory Seat/Mi rror Modul e i s connected to
the system through a seat wi ri ng harness that i nter-
faces wi l l al l of the components wi thi n the seat struc-
ture, and wi th el ectri cal di stri buti on wi ri ng harness
connecti ons to the non-seat mounted components.
The modul e operates the seat and recl i ner motors
through rel ays: four dedi cated to track forward/rear-
ward, track front up/down, track rear up/down, and
recl i ner forward/rearward. A fi fth rel ay control s the
di recti on of operati on of those motors.
POWER SIDE VIEW MIRROR POSITION SENSING
The mi rror swi tch on the i nstrument panel oper-
ates the outsi de rear vi ew mi rrors i ndependentl y of
the memory seat/mi rror modul e. The modul e acti -
vates the mi rror motors onl y when i n i ts recal l mode.
The si de vi ew mi rrors have posi ti on sensi ng rheo-
stats bui l t i nto each si de vi ew mi rror verti cal and
hori zontal motor assembl y. These rheostats provi de a
sense vol tage to the memory seat/mi rror modul e that
i ndi cates where the mi rror i s movi ng to or where i ts
posi ti on i s at when the modul e i s acti vated but the
mi rror motor i s not movi ng.
MEMORY SELECTOR SWITCHES
The memory sel ector swi tches are mounted on the
dri vers door tri m panel wi thi n easy reach of the
dri ver. They provi de a means to set or recal l ei ther of
two posi ti ons of seat and recl i ner, and the si de vi ew
mi rrors as chosen by the dri ver.
The i nputs from these swi tches to the memory
seat/mi rror modul e i s a ground l evel si gnal .
(1) Adjust the seat, recl i ner and si de vi ew mi rrors
to the desi red posi ti on.
(2) Press momentari l y and rel ease memory swi tch S.
(3) Press momentari l y and rel ease memory swi tch
1 or 2. Do NOT press any swi tches for 10 seconds.
(4) To program the second dri vers posi ti on, fol l ow
the above sequence.
(5) To recal l ei ther of the programmed posi ti ons
momentari l y press and rel ease ei ther memory sel ec-
tor swi tch 1 or 2.
DEFINITION OF: MOMENTARILY AND
RELEASE
The memory seat/mi rror modul e has swi tch i nput
ti mi ng requi rements of a mi ni mum press momen-
tari l y ti me of 250 mi l l i seconds fol l owed by a maxi -
mum hol d ti me of 5 seconds, fol l owed by a maxi mum
rel ease ti me between steps of 5 seconds that must be
met for proper operati on of the system.
SEAT AND RECLINER SWITCHES
The seat and recl i ner swi tch assembl y i s mounted
outboard on the seat si de-shi el d. Press and hol d the
desi red seat or recl i ner swi tch to effect movement.
The Memory Seat/Mi rror Modul e (MSM Modul e) wi l l
dri ve a maxi mum of 2 motors at a ti me i n a gi ven
di recti on. I f confl i cti ng di recti ons are requested, the
pri ori ty for response wi l l be as fol l ows:
Seat Track Rearward
Seat Front Down
Seat Rear Down
Recl i ner Rearward
Seat Track Forward
Seat Front Up
Seat Rear Up
Recl i ner Forward
The i nputs from these swi tches to the MSM Mod-
ul e i s a current l i mi ted battery source fed by the
MSM Modul e. Thi s protects the MSM Modul e pri nted
ci rcui t board traces from acti ng as fuses. Al l of these
swi tch contact i nputs to the modul e are normal l y
cl osed to ground, except when actuated.
POSITION SENSING SEAT AND RECLINER
POTENTIOMETERS
A potenti ometer i s mounted to each seat track and
recl i ner motor end-bel l to provi de a sense vol tage to
the Memory Seat/Mi rror Modul e that wi l l i ndi cate to
the modul e where the seat track or recl i ner i s posi -
ti oned.
Thi s sense vol tage i s deri ved from a 5 vol t source
provi ded by the modul e to the potenti ometer. The
sense vol tage i s i nput i nto the modul e and stored by
the Memory Seat/Mi rror Modul e.
MEMORY SELECTOR SWITCHES
To test the memory sel ector swi tch:
(1) Remove the memory sel ector swi tch. Refer to
removal procedure.
between swi tch pi ns. Refer to (Fi g. 1) for proper Pi n
numbers.
SIDE VIEW MIRROR SWITCH STUCK
The mi rror swi tches i n the i nstrument panel have
normal l y open contacts when i n thei r i nacti ve state.
The l eft/ri ght rocker swi tch has a center-off detent. I f
thi s swi tch i s actuated to ei ther si de, i t then becomes
connected to the P73/P70, ci rcui ts whi ch are the mi r-
ror motor common connecti ons. No faul ts wi l l resul t
from thi s acti on by i tsel f. I f one of the other swi tch
contacts from the round porti on of the swi tch
becomes acci dental l y cl osed, It can cause problems
such as both mirrors operating at the same
time in the vertical or horizontal modes.
Turn i gni ti on swi tch ON: I f two mi rror swi tch
contacts, from the round porti on, are stuck i n the
cl osed posi ti on, and the l eft/ri ght porti on i s actuated
to ei ther si de, a mi rror motor wi l l become actuated.
Thi s wi l l dri ve the motor to i ts stop, where i t wi l l
keep ratcheti ng unti l a swi tch contact i s rel eased or
the i gni ti on i s turned to OFF. Repl ace the mi rror
swi tch assembl y to correct thi s condi ti on.
Wi th the i gni ti on swi tch i n the ON or the OFF
posi ti on: I f onl y one mi rror swi tch contact i s stuck i n
the cl osed posi ti on, the mi rror motor wi l l not become
actuated. Duri ng an i gni ti on swi tch recal l of a dri v-
Fig. 1 Memory Selector Switch Continuity
ers chosen posi ti on, the Memory Seat/Mi rror Modul e
wi l l attempt to dri ve the mi rror motor onl y i f:
The cl osed swi tch contact was the same as the
desi red di recti on
Unti l the l ack of a si gnal seen by the modul e
shuts off the dri ve to the motor
The Memory Seat/Mi rror Modul e wi l l shut off the
dri ve to the desi red motor. I t i s possi bl e that a si ngl e
stuck contact coul d pl ace an opposi te mi rror or di rec-
ti on i nto a seri es connecti on. Thi s woul d run the con-
nected motors at approxi matel y hal f speed. Repl ace
the mi rror swi tch assembl y to correct thi s condi ti on.
The 25-way connector at the Memory Seat/Mi rror
Modul e (under the dri vers seat) and the mi rror
mechani zati on show that both mi rrors use the same
functi ons. The rheostat for posi ti on sensi ng uti l i zes
the wi re from the modul e to the mi rror as both feed
and sense l i ne on the same wi res, D and F. The
ground return wi re, E, stands al one. Refer to (Fi g. 2)
and the Mi rror Mechani zati on Tabl e.
The mi rror motors for each si de use a common con-
necti on, B, whi ch becomes automati cal l y connected to
the proper pol ari ty power connecti on duri ng ei ther
manual (through the mi rror swi tch) or recal l
(through the Memory Seat/Mi rror Modul e) modes of
operati on.
DIAGNOSTIC MODE
MODE 1
Di agnosti c Mode 1 cl ears soft l i mi ts and sets mem-
ory sel ector swi tches (1 and 2) to predetermi ned val -
ues.
Fig. 2 Mirror Mechanization
MIRROR MECHANIZATION TABLE
MIRROR PLANE MOTION RESISTANCE APPLIED POTENTIAL
A B C
UP E-F INCREASE OPEN
DOWN E-F DECREASE OPEN
RIGHT D-E INCREASE OPEN
LEFT D-E DECREASE OPEN
ACTIVATION- Press and hol d the S and 1 buttons
for 5 seconds to enter di agnosti c mode 1. Thi s mode
i s exi ted at the compl eti on of the mode 1 tasks or
upon groundi ng the RKE i nput to the Memory Seat/
Mi rror Modul e.
Mode 1 wi l l :
Cl ear al l soft l i mi ts to thei r defaul t hard l i mi t
val ues
Load memory 1 wi th defaul t setti ngs corre-
spondi ng to hori zontal rearward, front down, rear
down, and recl i ner rearward posi ti ons
Load memory 2 wi th defaul t setti ngs corre-
spondi ng to hori zontal forward, front up, rear up,
and recl i ner forward posi ti ons
MODE 2
Di agnosti c mode 2 provi des a way to determi ne i f
the seat/mi rror motors and posi ti on sensors are con-
nected properl y.
ACTIVATION- Press and hol d the S and 2 buttons
for 5 seconds to enter di agnosti c mode 2. Thi s mode
i s exi ted after 5 seconds of swi tch i nacti vi ty or upon
groundi ng the RKE i nput by movi ng the transmi s-
si on out of the PARK posi ti on.
Mode 2 wi l l :
Pl ace the seat and mi rror motors at thei r mi d-
poi nt
When a si ngl e axi s of seat or mi rror moti on i s
requested by pressi ng a swi tch, the correspondi ng
motor i s energi zed. Thi s tests swi tch i nput and motor
output
When the swi tch i s rel eased, the motor wi l l
automati cal l y return to i ts ori gi nal posi ti on. I f the
correspondi ng sensor i s out of range, then the motor
wi l l not return to i ts ori gi nal posi ti on. Thi s tests the
i ntegri ty of the sensors and motor outputs. Refer to
(Fi g. 3), (Fi g. 4), (Fi g. 5) and (Fi g. 6) for modul e con-
nector cal l outs.
Fig. 3 Memory Seat/Mirror Module
Fig. 4 Memory Seat/Mirror Module 10-Way Connector
CIRCUIT DESCRIPTION
Power to both dri ver and passenger seats, as wel l
as power door l ocks, rear bl ower, and front fog l amps
(i f so equi pped), i s provi ded by the A3 ci rcui t through
a 40 amp MAXI -fuse i n the Power Di stri buti on Cen-
ter (PDC) under the hood. I f al l of these devi ces are
nonfuncti onal , repl ace the MAXI -fuse. I f the new
MAXI -fuse bl ows i mmedi atel y, correct the wi ri ng
short to Ground that coul d be on any of those afore-
menti oned l oads before proceedi ng further.
Once the power i s back ON, i f the power seats sti l l
do not work, check the 30 amp ci rcui t breaker that i s
l ocated i n the dri vers seat wi ri ng harness approxi -
matel y 10 i nches from the 4-way connector. The
power feed ci rcui t to the 30 amp ci rcui t breaker i s 14
ga. A3 RD/WT.
Fol l owi ng the 30 amp ci rcui t breaker i s a 14 ga.
wi re desi gnated as F35 RD that provi des power i nto
the Memory Seat/Mi rror Modul e and i s doubl e
cri mped wi th a 14 ga. F35A RD that provi des power
to the passenger seat through the 4-way connector.
I f the power door l ocks, rear bl ower, and front fog
l amps (i f so equi pped) are functi onal and the seats
are both nonfuncti onal , repai r/repl ace the open wi r-
i ng and/or ci rcui t breaker i n the dri vers seat harness
to correct the condi ti on.
Ensure that the 12 ga. ground wi re Z1 BK from
the el ectri cal di stri buti on wi ri ng ground spl i ce i nto
the 4-way connector i s provi di ng ground. The Z1 BK
i s doubl e cri mped at the seat harness si de of the
4-way connector taki ng a 14 ga. Z1 BK i nto the
10-way connector (cavi ty 7) 14 ga. Thi s doubl e cri mp
carri es a 20 ga. Z1A BK to cavi ty 3 of the power seat
swi tch 10-way. I f the passenger power seat i s func-
ti onal , and the dri vers seat i s nonfuncti onal exami ne
the ci rcui t F35 RD from the doubl e cri mped ci rcui t
breaker connector i nto the 10-way connector cavi ty 8
of the control modul e for conti nui ty. Repai r or repl ace
as necessary. I f the dri vers seat i s sti l l nonfunc-
ti onal , use a mul ti -functi on meter to check the P9 RD
20 ga. ci rcui t from the control modul e 21-way connec-
tor (cavi ty 11) to the power seat swi tch 10-way con-
nector (cavi ty 5) This is a low current battery
feed from the control module that will not illu-
minate a test lamp.
Duri ng shi ppi ng of the vehi cl e, an M1 ci rcui t 10
amp fuse (l abel ed I OD) i s temporari l y removed from
the PDC i n the engi ne compartment to el i mi nate
unnecessary battery depl eti on. However, thi s fused
ci rcui t bei ng open (that feeds through the el ectri cal
di stri buti on wi ri ng to cavi ty 16 of the 25-way connec-
tor) wi l l not stop manual seat actuati ons from taki ng
pl ace (onl y recal l mode requests) duri ng shi ppi ng.
(1) I f the memory seat/mi rror modul e does not
respond wi th a rel ay cl i ck to any seat swi tch i nput
(as wel l as the desi red moti on) when actuated, pro-
ceed wi th the fol l owi ng anal ysi s:
Veri fy power ON F35 and ground Z1 i nto the
system as i ndi cated above.
Veri fy al l connectors are mated wi th the memory
seat/mi rror modul e.
Pl ace the vehi cl e gear shi ft l ever i n any posi ti on
except PARK (causes the Memory Seat/Mi rror Mod-
ul e to wake-up and provi de a posi ti on sense vol tage
to the seat motor potenti ometers and the mi rror
rheostat(s). Thi s vol tage can be checked at the appro-
pri ate cavi ti es of the 21 and 25-way connectors.
Veri fy the swi tch connector i s mated wi th the
seat swi tch on the i nsi de of the outboard si de-shi el d.
Veri fy battery vol tage at the P9 ci rcui t refer-
enced to the Z1A ground reference (cavi ty 1) of the
seat swi tch. I f P9 l ow current battery i s not avai l abl e
comi ng from the modul e, repl ace the Memory Seat/
Mi rror Modul e.
I f P9 l ow current battery i s present at (cavi ty 5)
referenced to ground Z1 (cavi ty 1) of the seat swi tch,
veri fy the presence of the P9 vol tage at the swi tch
outputs. I f there i s no output vol tage from the
swi tch, repl ace the swi tch.
I f P9 vol tage i s present at the output of the
swi tch, but there i s no reacti on from the memory
seat/mi rror modul e, veri fy that the P9 vol tage i s
present at the appropri ate 21-way connector pi ns
i nto the modul e. I f the P9 vol tage i s not present at
the 21-way connector, repai r or repl ace the seat wi r-
i ng harness. I f the veri fi cati on check of the seat wi r-
i ng harness i s correct, repl ace the control modul e.
(2) I f the control modul e does not respond wi th a
rel ay cl i ck to a speci fi c seat swi tch when actuated,
veri fy the conti nui ty of the parti cul ar ci rcui t between
the seat swi tch and the Memory Seat/Mi rror Modul e.
I f the P9 vol tage i s present at the correct i nput of the
21-way connector of the modul e when the swi tch i s
actuated, but there i s no response by the modul e,
repl ace the Memory Seat/Mi rror Modul e.
(3) I f the Memory Seat/Mi rror Modul e responds
wi th a rel ay cl i ck when a seat swi tch i s actuated for
a gi ven di recti on, but there i s no reacti on from a seat
or recl i ner motor rel ati ng to that swi tch i nput, di s-
connect the 10-way connector from the control mod-
ul e. Jumper the battery and ground from cavi ti es 8
and 7 of the seat harness 10-way connector to the
proper cavi ti es for the seat or recl i ner motor i n ques-
ti on and di recti on of travel desi red. I f the motor oper-
ates, repl ace the control modul e. I f the motor does
not operate, veri fy conti nui ty of the wi ri ng i nto the
motor 2-way connector. Repai r or repl ace the wi ri ng
as necessary. I f the wi ri ng has conti nui ty, and the
motor wi l l not operate when fed di rectl y, repl ace the
track assembl y, si nce the motor/transmi ssi on combi -
nati ons are not desi gned to be servi ced on an i ndi vi d-
ual basi s.
SEAT AND RECLINER POSITION SENSING
Seat and recl i ner posi ti on sense ground reference
ci rcui t P28 BR/RD feed i s from the memory seat/mi r-
ror modul e (cavi ty 10) 21-way connector to each of
the posi ti on sense connectors.
Seat and recl i ner posi ti on sense +5 vol t feed ci rcui t
P29 BR/WT feed i s from the memory seat/mi rror
modul e (cavi ty 20) 21-way connector to each of the
posi ti on sense connectors.
To test for the presence of a sense vol tage, a vol t
meter must be used as fol l ows:
Connect the negati ve probe to the P28 ci rcui t
(cavi ty 10) of the 21-way connector.
Connect the posi ti ve probe to the P29 ci rcui t
(cavi ty 20) of the 21-way connector and veri fy a vol t-
age readi ng between 3.5 and 5 vol ts when a seat or
recl i ner swi tch i s acti vated. An internal timer in
the Memory Seat/Mirror Module (MSM Module)
regulates the length of time this voltage stays
active i.e., 3 seconds from the time that the
switch was activated, unless the switch is held
or while the transmission is out of PARK. I f the
vol tage i s l ess than 3.5, there i s a faul t i n the system
that i s drawi ng i t down. To troubl eshoot thi s ci rcui t,
di sconnect the 25-way connector from the MSM Mod-
ul e (thi s removes al l of the vehi cl e mi rror ci rcui try).
I f the vol tage i s sti l l l ess than 3.5, di sconnect each of
the posi ti on sense connectors from each of the
motors. I f the vol tage remai ns l ess than 3.5, repl ace
the MSM Modul e. I f the vol tage i ncreases when a
motor i s di sconnected from the system, determi ne i f
the faul t i s i n the wi ri ng or the motor assembl y.
Repai r or repl ace the wi re harness assembl y as
needed. I f the faul t i s i n the motor posi ti on sensi ng
potenti ometer, repl ace the track assembl y.
The potenti ometers bui l t onto the motor end-bel l
provi de vol tages to the MSM Modul e through the
21-way connector, whi ch change as fol l ows, corre-
spondi ng to the gi ven seat actuati ons. Refer to Seat
Actuati ons Tabl e.
SERVICE PROCEDURES
REMOTE KEYLESS ENTRY (RKE) DATA LINK
The memory seat/mi rror modul e i nterfaces wi th
the RKE vi a a seri al data l i nk (si ngl e wi re). The pro-
grammi ng sequence to rel ate an RKE transmi tter to
the chosen seat, recl i ner and si de vi ew mi rror posi -
ti ons consi sts of the fol l owi ng steps:
(1) Adjust the seat, recl i ner and si de vi ew mi rrors
to the desi red posi ti on.
S.
1 or 2.
(4) Press momentari l y and rel ease a LOCK button
on an RKE transmi tter.
(5) To program the second dri vers posi ti on, fol l ow
the previ ous sequence wi th a second transmi tter.
(6) To recal l ei ther of the programmed posi ti ons
wi th an RKE transmi tter, press momentari l y and
rel ease an UNLOCK button on one of the pro-
grammed RKE transmi tters. An unprogrammed
RKE transmitter will have no effect on the sys-
tem.
(7) The RKE recei ver uses the seri al data l i nk to
noti fy the modul e of a request from a programmed
transmi tter, that an UNLOCK button has been
pressed. Thi s UNLOCK request (from a transmi tter
associ ated wi th ei ther swi tch 1 or 2) wi l l acti vate the
Memory Seat/Mi rror Modul e i n the recal l mode to
the val ues that are stored i n the modul es memory.
(8) Whenever the modul e recei ves a speci fi c data
stream from the RKE recei ver that i nvol ves the pro-
grammi ng of a new transmi tter i nto the RKE
recei ver, the modul e wi l l cl ear i ts nonvol ati l e memory
seat and recl i ner val ues for both memory 1 and 2
and wi l l defaul t to a l ocati on consi sti ng of seat track
rearward, seat verti cal ri sers down, and recl i ner for-
ward i n both memory 1 and 2. After thi s has
occurred, the customer must reprogram thei r desi red
seat and mi rror posi ti ons.
(9) A recal l i s possi bl e any ti me that the vehi cl e
transmi ssi on i s i n PARK. Thi s condi ti on i s moni tored
by the Body Control Modul e (BCM).
(10) A ground pl aced on the seri al data l i nk by the
BCM whenever that the transmi ssi on i s not i n
PARK, wi l l i nhi bi t a recal l request from the door
mounted memory swi tch 1 or 2 or the RKE recei ver
that was i ni ti ated by ei ther of the val i dl y pro-
grammed transmi tters.
NOTE: The module will abort a recall if the trans-
mission is moved out of the PARK position or if any
seat, recliner or memory switch is pressed.
MEMORY SWITCHES
REMOVAL
(1) I nsert a proper tool through the access sl ot
l ocated at the front forward edge of the swi tch bezel .
(2) Pry the swi tch out from the door tri m panel
openi ng.
(3) Di sconnect wi re connector from back of swi tch.
INSTALLATION
For i nstal l ati on. reverse the above procedures.
SEAT TRACK ASSEMBLY
Refer to Group 23, Body for Removal and I nstal l a-
ti on procedures.
SEAT ACTUATIONS TABLE
LOCATI ON POSI TI ON VOLTAGE READI NG
CAVI TY #8
CI RCUI T P26
SEAT TRACK FRONT UP
SEAT TRACK FRONT DOWN
VOLTAGE I NCREASES
VOLTAGE DECREASES
CAVI TY #7
CI RCUI T P27
SEAT TRACK REAR UP
SEAT TRACK REAR DOWN
VOLTAGE I NCREASES
VOLTAGE DECREASES
CAVI TY #18
CI RCUI T P25
TRACK HORI ZONTAL FORWARD
TRACK HORI ZONTAL REARWARD
VOLTAGE I NCREASES
VOLTAGE DECREASES
CAVI TY #17
CI RCUI T P47
RECLI NER FORWARD
RECLI NER REARWARD
VOLTAGE I NCREASES
VOLTAGE DECREASES
POWER MIRRORS
CONTENTS
page page
GENERAL INFORMATION
HEATED MIRROR . . . . . . . . . . . . . . . . . . . . . . . . 1
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . 1
MEMORY MIRRORS . . . . . . . . . . . . . . . . . . . . . . 1
HEATED MIRROR TEST . . . . . . . . . . . . . . . . . . . 1
MIRROR MOTOR TEST . . . . . . . . . . . . . . . . . . . 1
MIRROR SWITCH TEST . . . . . . . . . . . . . . . . . . . 1
POWER MIRROR SWITCH . . . . . . . . . . . . . . . . . 3
POWER MIRROR . . . . . . . . . . . . . . . . . . . . . . . . 3
GENERAL INFORMATION
INTRODUCTION
El ectri cal l y-operated remote control mi rrors are
control l ed by a swi tch assembl y l ocated on the head-
l amp swi tch bezel i n the i nstrument panel .
The vehi cl e uses a rocker swi tch for ri ght or l eft
si de mi rror sel ecti on and a si ngl e pl atform button for
mi rror UP, DOWN, RI GHT, or LEFT movement.
The motors whi ch operate the mi rrors are part of
the mi rror assembl y and cannot be servi ced sepa-
ratel y.
HEATED MIRROR
Heated mi rrors are avai l abl e on model s wi th
Power Mi rrors and Rear Wi ndow Defogger onl y. The
heated mi rror i s control l ed by the rear wi ndow defog-
ger swi tch. The heated mi rror i s ON when the rear
wi ndow defogger i s ON.
MEMORY MIRRORS
For memory mi rrors refer to Group 8R, Power
Seats secti on Memory Seat/Mi rror system.
MIRROR MOTOR TEST
(1) Remove headl amp swi tch bezel . Refer to Group
8E, I nstrument Panel and Gauges.
(2) Di sconnect wi ri ng harness connector to the
power mi rror swi tch and headl amp swi tch.
(3) Usi ng two jumper wi res:
Connect one to a 12-vol t source
Connect the other to a good body ground
Refer to the Mi rror Test Chart for wi re hookups
at the swi tch connector (Fi g. 1).
(4) I f resul ts shown i n chart are not obtai ned,
check for broken or shorted ci rcui t, or repl ace mi rror
assembl y as necessary.
MIRROR SWITCH TEST
(1) Remove power mi rror swi tch from mounti ng
posi ti on.
(2) Di sconnect wi ri ng harness at swi tch connector.
(3) Usi ng a ohmmeter, test for conti nui ty between
the termi nal s of the swi tch as shown i n the Mi rror
Swi tch Conti nui ty Chart (Fi g. 2).
(4) I f resul ts shown i n the chart are not obtai ned,
repl ace the swi tch.
HEATED MIRROR TEST
Heated mi rrors are avai l abl e on model s wi th
Power Mi rrors and Rear Wi ndow Defogger onl y. The
heated mi rror i s control l ed by the rear wi ndow defog-
ger swi tch. The heated mi rror i s ON when the rear
wi ndow defogger i s ON.
TEST PROCEDURE
(1) The mi rror shoul d be warm to the touch.
(2) I f not, check the 10 amp fuse (12) i n the junc-
ti on bl ock behi nd the i nstrument panel to the l eft of
the steeri ng col umn.
(3) Test vol tage at rear wi ndow defogger swi tch.
I f no vol tage repai r wi re.
Appl y vol tage to one wi re and ground the other,
refer to (Fi g. 1) for pi n numbers. Mi rror shoul d
become warm to the touch.
I f not remove mi rror gl ass and test the wi res for
conti nui ty. I f no conti nui ty repai r wi res.
I f wi res are OK, repl ace mi rror gl ass.
To test defogger swi tch refer to Group 8N, El ec-
tri cal l y Heated Systems.
NS POWER MIRRORS 8T - 1
Fig. 1 Power Mirror Test
Fig. 2 Mirror Switch Test
8T - 2 POWER MIRRORS NS
POWER MIRROR
REMOVAL
(1) Remove front cover, refer to (Fi g. 3).
(2) Remove attachi ng screws.
(3) Di sconnect wi re connector(s).
(4) Remove mi rror from vehi cl e.
INSTALLATION
POWER MIRROR SWITCH
Refer to Group 8E, I nstrument Panel and Systems
for servi ce procedure (Fi g. 4).
Fig. 3 Power Side View Mirror
Fig. 4 Power Mirror/Window Switch
NS POWER MIRRORS 8T - 3
CHIME WARNING/REMINDER SYSTEM
CONTENTS
page page
GENERAL INFORMATION
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . 1
CHIME SYSTEM DIAGNOSIS . . . . . . . . . . . . . . . 1
DOME LAMP ON CHIME . . . . . . . . . . . . . . . . . . 2
ENGINE TEMPERATURE CRITICAL CHIME . . . . 2
EXTERIOR LAMPS ON CHIME . . . . . . . . . . . . . . 2
KEY-IN IGNITION CHIME . . . . . . . . . . . . . . . . . . 2
LOW OIL PRESSURE CHIME OPERATION . . . . . 2
SEAT BELT CHIME . . . . . . . . . . . . . . . . . . . . . . . 2
SEAT BELT LAMP . . . . . . . . . . . . . . . . . . . . . . . . 2
TURN SIGNAL ON CHIME . . . . . . . . . . . . . . . . . 3
WARNING LAMP ANNOUNCEMENT CHIME . . . 3
GENERAL INFORMATION
INTRODUCTION
WARNING: ON VEHICLES EQUIPPED WITH AN
AIRBAG, REFER TO GROUP 8M, RESTRAINT SYS-
TEMS FOR SAFETY PRECAUTIONS AND WARN-
INGS TO OBSERVE WHEN SERVICING AIRBAG
RELATED COMPONENTS.
The chi me system provi des the dri ver wi th warn-
i ng chi mes for:
Seat Bel t
Exteri or Lamps ON
Key-I n I gni ti on
Engi ne Temperature Cri ti cal
Turn Si gnal s ON
Dome Lamp ON
Low Oi l Pressure
Hi gh Speed Warni ng
Warni ng Lamp Announcement
The Chi me Warni ng/Remi nder System i s di agnosed
usi ng a scan tool (DRB). Refer to the proper Body
Di agnosti c Procedures manual for testi ng procedures
and scan tool usage i nstructi ons.
CHIME SYSTEM DIAGNOSIS
NO TONE WHEN IGNITION SWITCH IS
TURNED ON AND DRIVERS SEAT BELT IS
NOT BUCKLED.
(1) Usi ng a scan tool (DRB), check for tone i n any
other functi on.
(2) Usi ng a vol tmeter, check for vol tage:
(a) Pi n 9 of the i nternal 32 way connector of the
BCM for battery feed.
(b) Pi n 8 of the i nternal 32 way connector of the
BCM for i gni ti on feed.
(c) I f vol tage OK, go to step Step 3
(d) I f NO vol tage repai r as necessary. Refer to
Group 8W, Wi ri ng Di agrams for component l oca-
ti ons and ci rcui t i nformati on.
(3) Check dri vers seat bel t buckl e swi tch i nput for
a cl osed ci rcui t when not buckl ed. I f i nput not seen,
l ook for open i n wi ri ng or swi tch. The swi tch i s
grounded when bel t i s not buckl ed.
(4) Repai r as necessary.
NO FASTEN SEAT BELT LAMP WHEN
IGNITION SWITCH IS TURNED ON.
(1) Check for burned out l amp.
(2) Usi ng a vol tmeter check for vol tage:
(a) Pi n 2 of the mechani cal i nstrument cl uster
for battery feed.
(b) Pi n 11 of the mechani cal i nstrument cl uster
for i gni ti on vol tage.
FASTEN SEAT BELT LAMP OR TONE
CONTINUES FOR MORE THAN 10 SECONDS
AFTER SEAT BELTS ARE FASTENED AND
DRIVERS DOOR IS CLOSED.
(1) Check l eft door ajar swi tch for no ground when
swi tch i s depressed.
(a) I f conti nui ty repl ace door ajar swi tch.
(b) I f NO conti nui ty repl ace BCM for tone condi -
ti on, or repl ace mechani cal i nstrument panel for
l amp condi ti on.
(c) Repl ace BCM for tone condi ti on.
(d) Repl ace mechani cal i nstrument cl uster for
l amp condi ti on.
NO TONE WHEN PARK OR HEADLAMPS ARE
ON AND DRIVERS DOOR IS OPEN.
(1) Check l eft door ajar swi tch for good ground
when dri vers door i s open. Repai r as necessary.
NS CHIME WARNING/REMINDER SYSTEM 8U - 1
(2) I nspect BCM connectors and wi res for proper
connecti on. I f OK, repl ace BCM for tone condi ti on.
DOME LAMP ON CHIME
The dome l amp on chi me wi l l warn the dri ver that
the dome l amps have been l eft on.
Wi th the i gni ti on i s OFF:
Dri vers door OPEN (door ajar swi tch i s cl osed to
ground)
Dome l amps are ON (dome l amp swi tch i s cl osed
to ground),
The chi me wi l l sound conti nuousl y unti l dri vers
door i s cl osed, dome l amps tuned OFF or unti l the
battery protecti on ti me out of 15 mi nutes has
expi red. Refer Group 8L, Lamps proper procedures.
Chi me rate: 168 to 192 chi mes per mi nute.
ENGINE TEMPERATURE CRITICAL CHIME
The engi ne temperature cri ti cal chi me wi l l warn
the dri ver that the vehi cl es engi ne i s overheati ng.
Whi l e moni tori ng the cool ant temperature, the Pow-
ertrai n Control Modul e (PCM) wi l l send on the CCD
bus as engi ne temperature every 1.376 seconds to the
Body Control Modul e (BCM). The BCM cal cul ates
engi ne temperature and determi nes i f a warni ng
shoul d occur. Thi s feature i s functi onal onl y wi th the
I gni ti on Swi tch i n the Run/Start posi ti on.
When the engi ne temperature reaches 122C
(252F) the BCM wi l l chi me one tone and the engi ne
temperature l amp comes ON. The BCM turns OFF
the l amp when the engi ne temperature reaches
117C (242F). The BCM wi l l chi me conti nuousl y
when the engi ne temperature reaches 125C (257F).
The chi me wi l l turn OFF after four mi nutes or when
the temperature reaches 117C (242F), whi ch ever
occurs fi rst.
EXTERIOR LAMPS ON CHIME
The exteri or l amp on chi me wi l l warn the dri ver
that the exteri or l i ghts have been l eft on.
Wi th the i gni ti on swi tch OFF:
Dri vers door i s open (door ajar swi tch i s cl osed
to ground)
Parki ng l amps or headl amps ON (parki ng l amp
swi tch i s cl osed to ground)
The chi me wi l l sound unti l l i ghts are turned OFF,
dri vers door cl osed or unti l the battery protecti on
ti me out of 3 mi nutes has expi red.
Refer to Group 8L, Lamps, for proper servi ce pro-
cedures. Chi me rate: 168 to 192 chi mes per mi nute.
To test the exteri or l amps l eft on functi on:
Turn i gni ti on off
Remove i gni ti on key
Turn exteri or l amps on wi th dri vers door open.
Chi me shoul d sound unti l l amps are turned off or
dri vers door i s cl osed.
KEY-IN IGNITION CHIME
The key-i n i gni ti on chi me wi l l act as a warni ng to
the dri ver that the i gni ti on key has been l eft i n the
i gni ti on swi tch.
Wi th the i gni ti on swi tch i s i n OFF posi ti on ONLY:
Dri vers door i s open/ajar (door ajar swi tch i s
cl osed to ground)
Key i s i n the i gni ti on swi tch (key-i n i gni ti on
The chi me wi l l sound unti l one of the above condi -
ti ons i s removed. Chi me rate: 168 to 192 chi mes per
mi nute.
To test the key-i n i gni ti on functi on, i nsert key i nto
the i gni ti on and open dri vers door. Do not turn i gni -
ti on ON. Chi me shoul d sound unti l key i s removed
from i gni ti on or dri vers door i s cl osed.
LOW OIL PRESSURE CHIME OPERATION
The l ow oi l pressure chi me wi l l warn the dri ver
that the engi ne oi l pressure i s l ow. The oi l pressure
swi tch, wi l l cl ose to ground duri ng a l ow oi l pressure
condi ti on. The oi l pressure l amp wi l l i l l umi nate i n
the message center. The body control modul e wi l l
moni tor the oi l pressure swi tch and si gnal a l ow oi l
pressure condi ti on. A conti nuous four mi nute warn-
i ng chi me wi l l sound and the oi l pressure l amp wi l l
come ON when the fol l owi ng condi ti ons are met:
I gni ti on on and engi ne not cranki ng
Engi ne runni ng at 420 to 480 rpm for 10 sec-
onds
Oi l pressure swi tch cl osed to ground for (1 sec-
ond mi ni mum, 2 seconds maxi mum)
SEAT BELT CHIME
The seat bel t chi me wi l l sound for 4 to 8 seconds,
when the i gni ti on i s turned on and the dri vers seat
bel t i s not buckl ed (seat bel t swi tch i s cl osed to
ground). Thi s i s a remi nder to the dri ver to buckl e
the seat bel t. The seat bel t l amp i s control l ed by the
mechani cal i nstrument cl uster. The cl uster wi l l al so
i l l umi nate the seat bel t warni ng l amp for 6 seconds.
Buckl i ng the dri vers seat bel t before the ti me out
has expi red wi l l cause the chi me to stop i mmedi atel y.
To test the seat bel t warni ng system, the i gni ti on
swi tch must be i n the OFF posi ti on for 1 mi nute
before starti ng the test. Turn the i gni ti on swi tch to
the on posi ti on wi th the dri vers seat bel t not buck-
l ed. The seat bel t warni ng l amp shoul d l i ght and the
chi me shoul d sound 4 to 8 seconds.
SEAT BELT LAMP
The seat bel t l amp i n the i nstrument cl uster si g-
nal s the vehi cl e passengers to fasten thei r seat bel ts.
The seat bel t l amp i s i l l umi nated di rectl y by the
8U - 2 CHIME WARNING/REMINDER SYSTEM NS
i nstrument cl uster for 6 seconds after the i nstrument
cl uster recei ves the message from the Body Control
Modul e. The seat bel t l amp i s therefore i l l umi nated
for 6 seconds whenever the i gni ti on swi tch i s moved
to run/start posi ti on.
(1) Whi l e i gni ti on i s off, the seat bel t l amp wi l l not
be i l l umi nated.
(2) The i gni ti on power feed status wi l l be updated
every 250 mi l l i seconds or on change.
(3) Thi s l amp wi l l be checked by the i nstrument
cl uster for 6 seconds wi th every run/start cycl e of the
TURN SIGNAL ON CHIME
The turn si gnal on chi me wi l l warn the dri ver that
the turn si gnal s have been l eft on. When the body
control modul e recei ves a turn si gnal i nput for 6.4
km (4.0 mi l es), vehi cl e speed i s greater than 24 km/h
(15 mph), the chi me wi l l sound conti nuousl y unti l the
turn si gnal i s turned OFF. I f vehi cl e speed drops
bel ow 24 km/h (15 mph) pri or to the warni ng bei ng
acti vated, the accumul ated di stance travel ed wi l l be
reset. The turn si gnal chi me i s not acti vated when
the emergency fl ashers are turned on. Thi s feature
can al so be di sabl ed i n EEPROM. Chi me rate: 50
chi mes per mi nute.
For the turn si gnal warni ng system to operate:
Must have i nput from ei ther the ri ght or l eft
turn si gnal l amps. Creates a vol tage change between
0 and battery vol tage.
The vehi cl e speed sensor sends a message to the
Powertrai n Control Modul e that vehi cl e has exceeded
24 km/h (15 mph) for 6.4 km (4.0 mi l es).
When the above two condi ti ons are met, the
chi me wi l l sound. The chi me wi l l stop when no fur-
ther vol tage change i s detected.
I f hazard warni ng si gnal s are pul si ng, no chi me
wi l l sound.
I f speed drops bel ow 24 km/h (15 mph) before
the warni ng i s i ssued, the warni ng wi l l not be i ssued
and the di stance counter wi l l be reset.
I f turn si gnal l amps are not worki ng properl y,
the chi me wi l l not sound.
When usi ng the scan tool , refer to the proper
Body Di agnosti c Manual for the procedure.
WARNING LAMP ANNOUNCEMENT CHIME
The warni ng l amp announcement chi me wi l l warn
the dri ver to scan the i nstrument cl uster to observe
whi ch warni ng l amp i s i l l umi nated. Whenever the
vol ts, l ow fuel , l ow washer/cool ant l evel , door ajar or
gate ajar l amps are fi rst i l l umi nated, the chi me wi l l
sound one tone. The door/l i ftgate ajar warni ng l amp
announcement chi me sounds onl y i f the vehi cl e speed
i s above 2 m.p.h.
Two seconds after i gni ti on swi tch i s turned ON or
unti l the seat bel t warni ng chi me ends, al l warni ng
announcement chi mes wi l l be consol i dated i nto one
warni ng announcement. Thi s wi l l occur 2 seconds
after the seat bel t warni ng chi me ends. I f a warni ng
announcement shoul d occur whi l e another warni ng
chi me i n progress (turn si gnal , l ow oi l pressure or
hi gh speed warni ngs), no addi ti onal chi mes wi l l
sound after the chi me i n progress ends. Al l associ -
ated l amps wi l l be i l l umi nated, and the acti ve chi me
wi l l be the warni ng announcement.
NS CHIME WARNING/REMINDER SYSTEM 8U - 3
CHIME WARNING/REMINDER SYSTEM
CONTENTS
page page
GENERAL INFORMATION
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . 1
CATALYST OVERHEAT WARNING CHIME . . . . 1
CHIME SYSTEM DIAGNOSIS . . . . . . . . . . . . . . 1
DOME LAMP ON CHIME . . . . . . . . . . . . . . . . . 2
ENGINE TEMPERATURE CRITICAL CHIME . . . 2
EXTERIOR LAMPS ON CHIME . . . . . . . . . . . . . 2
KEY-IN IGNITION CHIME . . . . . . . . . . . . . . . . . 2
LOW OIL PRESSURE CHIME OPERATION . . . 2
SEAT BELT CHIME . . . . . . . . . . . . . . . . . . . . . . 3
SEAT BELT LAMP . . . . . . . . . . . . . . . . . . . . . . 3
TURN SIGNAL ON CHIME . . . . . . . . . . . . . . . . 3
WARNING LAMP ANNOUNCEMENT CHIME . . 3
GENERAL INFORMATION
INTRODUCTION
WARNING: ON VEHICLES EQUIPPED WITH AN
AIRBAG, REFER TO GROUP 8M, RESTRAINT SYS-
TEMS FOR SAFETY PRECAUTIONS AND WARN-
INGS TO OBSERVE WHEN SERVICING AIRBAG
RELATED COMPONENTS.
The chi me system provi des the dri ver wi th warn-
i ng chi mes for:
Seat Bel t
Exteri or Lamps ON
Key-I n I gni ti on
Engi ne Temperature Cri ti cal
Turn Si gnal s ON
Dome Lamp ON
Low Oi l Pressure
Hi gh Speed Warni ng
Warni ng Lamp Announcement
Catal yst Overheati ng
The Chi me Warni ng/Remi nder System i s di agnosed
usi ng a scan tool (DRB). Refer to the proper Body
Di agnosti c Procedures manual for testi ng procedures
and scan tool usage i nstructi ons.
CATALYST OVERHEAT WARNING CHIME
The Catal yst Overheat Warni ng Chi me wi l l act as
a warni ng to the dri ver that the vehi cl es catal yst
has entered an overheat condi ti on. The Powertrai n
Control Modul e (PCM) wi l l enabl e or di sabl e thi s fea-
ture for the appropri ate vehi cl es. Ri ght hand dri ve
gas vehi cl es onl y. The Body Control Modul e (BCM)
wi l l moni tor the CCD bus for status and si gnal a cat-
al yst overheat condi ti on wi th conti nuous warni ng
chi me when the fol l owi ng condi ti ons are met:
I gni ti on swi tch i n the ON posi ti on
onds
CCD status and wi th a chi me rate of one chi me
per second.
CHIME SYSTEM DIAGNOSIS
NO TONE WHEN IGNITION SWITCH IS
TURNED ON AND DRIVERS SEAT BELT IS
NOT BUCKLED.
(1) Usi ng a scan tool (DRB), check for tone i n any
other functi on.
(2) Usi ng a vol tmeter, check for vol tage:
(a) Pi n 9 of the i nternal 32 way connector of the
BCM for battery feed.
(b) Pi n 8 of the i nternal 32 way connector of the
BCM for i gni ti on feed.
(c) I f vol tage OK, go to step Step 3
(d) I f NO vol tage repai r as necessary. Refer to
Group 8W, Wi ri ng Di agrams for component l oca-
ti ons and ci rcui t i nformati on.
(3) Check dri vers seat bel t buckl e swi tch i nput for
a cl osed ci rcui t when not buckl ed. I f i nput not seen,
l ook for open i n wi ri ng or swi tch. The swi tch i s
grounded when bel t i s not buckl ed.
NO FASTEN SEAT BELT LAMP WHEN
IGNITION SWITCH IS TURNED ON.
(1) Check for burned out l amp.
(2) Usi ng a vol tmeter check for vol tage:
(a) Pi n 2 of the mechani cal i nstrument cl uster
for battery feed.
(b) Pi n 11 of the mechani cal i nstrument cl uster
for i gni ti on vol tage.
NS/GS CHIME WARNING/REMINDER SYSTEM 8U - 1
FASTEN SEAT BELT LAMP OR TONE
CONTINUES FOR MORE THAN 10 SECONDS
AFTER SEAT BELTS ARE FASTENED AND
DRIVERS DOOR IS CLOSED.
(1) Check l eft door ajar swi tch for no ground when
swi tch i s depressed.
(a) I f conti nui ty repl ace door ajar swi tch.
(b) I f NO conti nui ty repl ace BCM for tone condi -
ti on, or repl ace mechani cal i nstrument panel for
l amp condi ti on.
(c) Repl ace BCM for tone condi ti on.
(d) Repl ace mechani cal i nstrument cl uster for
l amp condi ti on.
NO TONE WHEN PARK OR HEADLAMPS ARE
ON AND DRIVERS DOOR IS OPEN.
(1) Check l eft door ajar swi tch for good ground
when dri vers door i s open. Repai r as necessary.
(2) I nspect BCM connectors and wi res for proper
connecti on. I f OK, repl ace BCM for tone condi ti on.
DOME LAMP ON CHIME
The dome l amp on chi me wi l l warn the dri ver that
the dome l amps have been l eft on.
Wi th the i gni ti on i s OFF:
Dri vers door OPEN (door ajar swi tch i s cl osed to
ground)
Dome l amps are ON (dome l amp swi tch i s cl osed
to ground),
The chi me wi l l sound conti nuousl y unti l dri vers
door i s cl osed, dome l amps tuned OFF or unti l the
battery protecti on ti me out of 15 mi nutes has
expi red. Refer Group 8L, Lamps proper procedures.
ENGINE TEMPERATURE CRITICAL CHIME
The engi ne temperature cri ti cal chi me wi l l warn
the dri ver that the vehi cl es engi ne i s overheati ng.
Whi l e moni tori ng the cool ant temperature, the Pow-
ertrai n Control Modul e (PCM) wi l l send on the CCD
bus as engi ne temperature every 1.376 seconds to the
Body Control Modul e (BCM). The BCM cal cul ates
engi ne temperature and determi nes i f a warni ng
shoul d occur. Thi s feature i s functi onal onl y wi th the
I gni ti on Swi tch i n the Run/Start posi ti on. On the
Di esel vehi cl es, the cool ant temperature sensor i s
read di rectl y by the BCM.
When the engi ne temperature reaches 122C
(252F) or the di esel engi ne 112C (234F), the BCM
wi l l chi me one tone and the engi ne temperature l amp
comes ON. The BCM turns OFF the l amp when the
engi ne temperature reaches 117C (242F) or the di e-
sel engi ne 108C (226F). The BCM wi l l chi me con-
ti nuousl y when the engi ne temperature reaches
125C (257F) or di esel engi ne 116C (241F). The
chi me wi l l turn OFF after four mi nutes or when the
temperature reaches 117C (242F) or di esel engi ne
108C (226F), whi ch ever occurs fi rst.
EXTERIOR LAMPS ON CHIME
The exteri or l amp on chi me wi l l warn the dri ver
that the exteri or l i ghts have been l eft on.
Wi th the i gni ti on swi tch OFF:
Dri vers door i s open (door ajar swi tch i s cl osed
to ground)
Parki ng l amps or headl amps ON (parki ng l amp
The chi me wi l l sound unti l l i ghts are turned OFF,
dri vers door cl osed or unti l the battery protecti on
ti me out of 3 mi nutes has expi red.
Refer to Group 8L, Lamps, for proper servi ce pro-
cedures. Chi me rate: 168 to 192 chi mes per mi nute.
To test the exteri or l amps l eft on functi on:
Turn i gni ti on off
Remove i gni ti on key
Turn exteri or l amps on wi th dri vers door open.
Chi me shoul d sound unti l l amps are turned off or
dri vers door i s cl osed.
KEY-IN IGNITION CHIME
The key-i n i gni ti on chi me wi l l act as a warni ng to
the dri ver that the i gni ti on key has been l eft i n the
Wi th the i gni ti on swi tch i s i n OFF posi ti on ONLY:
Dri vers door i s open/ajar (door ajar swi tch i s
cl osed to ground)
Key i s i n the i gni ti on swi tch (key-i n i gni ti on
The chi me wi l l sound unti l one of the above condi -
ti ons i s removed. Chi me rate: 168 to 192 chi mes per
mi nute.
To test the key-i n i gni ti on functi on, i nsert key i nto
the i gni ti on and open dri vers door. Do not turn i gni -
ti on ON. Chi me shoul d sound unti l key i s removed
from i gni ti on or dri vers door i s cl osed.
LOW OIL PRESSURE CHIME OPERATION
The l ow oi l pressure chi me wi l l warn the dri ver
that the engi ne oi l pressure i s l ow. The oi l pressure
swi tch, wi l l cl ose to ground duri ng a l ow oi l pressure
condi ti on. The oi l pressure l amp wi l l i l l umi nate i n
the message center. The body control modul e wi l l
moni tor the oi l pressure swi tch and si gnal a l ow oi l
pressure condi ti on. A conti nuous four mi nute warn-
i ng chi me wi l l sound and the oi l pressure l amp wi l l
come ON when the fol l owi ng condi ti ons are met:
I gni ti on on and engi ne not cranki ng
onds
Oi l pressure swi tch cl osed to ground for (1 sec-
ond mi ni mum, 2 seconds maxi mum)
8U - 2 CHIME WARNING/REMINDER SYSTEM NS/GS
SEAT BELT CHIME
The seat bel t chi me wi l l sound for 4 to 8 seconds,
when the i gni ti on i s turned on and the dri vers seat
bel t i s not buckl ed (seat bel t swi tch i s cl osed to
ground). Thi s i s a remi nder to the dri ver to buckl e
the seat bel t. The seat bel t l amp i s control l ed by the
mechani cal i nstrument cl uster. The cl uster wi l l al so
i l l umi nate the seat bel t warni ng l amp for 6 seconds.
Buckl i ng the dri vers seat bel t before the ti me out
has expi red wi l l cause the chi me to stop i mmedi atel y.
To test the seat bel t warni ng system, the i gni ti on
swi tch must be i n the OFF posi ti on for 1 mi nute
before starti ng the test. Turn the i gni ti on swi tch to
the on posi ti on wi th the dri vers seat bel t not buck-
l ed. The seat bel t warni ng l amp shoul d l i ght and the
chi me shoul d sound 4 to 8 seconds.
SEAT BELT LAMP
The seat bel t l amp i n the i nstrument cl uster si g-
nal s the vehi cl e passengers to fasten thei r seat bel ts.
The seat bel t l amp i s i l l umi nated di rectl y by the
i nstrument cl uster for 6 seconds after the i nstrument
cl uster recei ves the message from the Body Control
Modul e. The seat bel t l amp i s therefore i l l umi nated
for 6 seconds whenever the i gni ti on swi tch i s moved
to run/start posi ti on.
(1) Whi l e i gni ti on i s off, the seat bel t l amp wi l l not
be i l l umi nated.
(2) The i gni ti on power feed status wi l l be updated
every 250 mi l l i seconds or on change.
(3) Thi s l amp wi l l be checked by the i nstrument
cl uster for 6 seconds wi th every run/start cycl e of the
TURN SIGNAL ON CHIME
The turn si gnal on chi me wi l l warn the dri ver that
the turn si gnal s have been l eft on. When the Body
Control Modul e recei ves a turn si gnal i nput for 1.6
km (1.0 mi l es), vehi cl e speed i s greater than 24 km/h
(15 mph), the chi me wi l l sound conti nuousl y unti l the
turn si gnal i s turned OFF. I f vehi cl e speed drops
bel ow 24 km/h (15 mph) pri or to the warni ng bei ng
acti vated, the accumul ated di stance travel ed wi l l be
reset. The turn si gnal chi me i s not acti vated when
the emergency fl ashers are turned on. Thi s feature
can al so be di sabl ed i n EEPROM. Chi me rate: 38 to
62 chi mes per mi nute.
For the turn si gnal warni ng system to operate:
Must have i nput from ei ther the ri ght or l eft
turn si gnal l amps. Creates a vol tage change between
0 and battery vol tage.
The vehi cl e speed sensor sends a message to the
Powertrai n Control Modul e that vehi cl e has exceeded
24 km/h (15 mph) for 1.6 km (1.0 mi l es).
When the above two condi ti ons are met, the
chi me wi l l sound. The chi me wi l l stop when no fur-
ther vol tage change i s detected.
I f hazard warni ng si gnal s are pul si ng, no chi me
wi l l sound.
I f speed drops bel ow 24 km/h (15 mph) before
the warni ng i s i ssued, the warni ng wi l l not be i ssued
and the di stance counter wi l l be reset.
I f turn si gnal l amps are not worki ng properl y,
the chi me wi l l not sound.
When usi ng the scan tool , refer to the proper
Body Di agnosti c Manual for the procedure.
WARNING LAMP ANNOUNCEMENT CHIME
The warni ng l amp announcement chi me wi l l warn
the dri ver to scan the i nstrument cl uster to observe
whi ch warni ng l amp i s i l l umi nated. Whenever the
vol ts, l ow fuel , l ow washer fl ui d, cool ant l evel (gas/
di esel ), l ow cool ant l evel , engi ne temperature hi gh
(di esel onl y), door ajar or gate ajar l amps are fi rst
i l l umi nated, the chi me wi l l sound one tone. The door/
l i ftgate ajar warni ng l amp announcement chi me
sounds onl y i f the vehi cl e speed i s above 2 m.p.h.
Two seconds after i gni ti on swi tch i s turned ON or
unti l the seat bel t warni ng chi me ends, al l warni ng
announcement chi mes wi l l be consol i dated i nto one
warni ng announcement. Thi s wi l l occur 2 seconds
after the seat bel t warni ng chi me ends. I f a warni ng
announcement shoul d occur whi l e another warni ng
chi me i n progress (turn si gnal , l ow oi l pressure or
hi gh speed warni ngs), no addi ti onal chi mes wi l l
sound after the chi me i n progress ends. Al l associ -
ated l amps wi l l be i l l umi nated, and the acti ve chi me
wi l l be the warni ng announcement.
NS/GS CHIME WARNING/REMINDER SYSTEM 8U - 3
OVERHEAD CONSOLE
CONTENTS
page page
COMPASS MINI-TRIP COMPUTER (CMTC) . . . . 1
COMPASS/TEMPERATURE MINI TRIP
COMPUTER SELF-DIAGNOSTIC TEST . . . . . . . 1
THERMOMETER AND COMPASS . . . . . . . . . . . . 2
UNIVERSAL TRANSMITTER . . . . . . . . . . . . . . . . 2
READING/DOME LAMP DIAGNOSIS . . . . . . . . . 3
TRAVELER MESSAGES . . . . . . . . . . . . . . . . . . . . 3
SERVICE PROCEDURES
COMPASS CALIBRATION PROCEDURE (FAST
METHOD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
COMPASS CALIBRATION PROCEDURE . . . . . . . 4
DEMAGNETIZING PROCEDURE . . . . . . . . . . . . . 4
AMBIENT TEMPERATURE SENSOR . . . . . . . . . . 5
COMPASS MINI-TRIP COMPUTER (CMTC)
LAMP BULBS . . . . . . . . . . . . . . . . . . . . . . . . . 6
MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
FRONT HEADER READING/COURTESY LAMP . . 6
OVERHEAD CONSOLE . . . . . . . . . . . . . . . . . . . . 6
READING/COURTESY LAMP ASSEMBLY . . . . . . 7
READING/COURTESY LAMP . . . . . . . . . . . . . . . 6
SPECIAL TOOLS
SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . 9
COMPASS/TEMPERATURE MINI TRIP COMPUTER
SELF-DIAGNOSTIC TEST
The CMTC i s capabl e of performi ng a di agnosti c
sel f check on many of i ts i nternal functi ons. CMTC
di agnosti cs may be performed usi ng a scan tool
(DRB) and the proper Body Di agnosti c Procedures
manual or by the fol l owi ng procedure.
(1) Wi th the i gni ti on swi tch i n the OFF posi ti on,
press both the US/M and STEP button.
(2) Turn i gni ti on swi tch to the ON posi ti on.
The CMTC wi l l perform i nternal checks whi l e
l i ghti ng al l segments of the vacuum fl orescent di s-
pl ay. Upon compl eti on of the i nternal check, the
CMTC wi l l di spl ay.
PASS
FAI L
CCd
I f any segment of the CMTC fai l s to l i ght repl ace
the modul e.
I f FAI L i s di spl ayed, repl ace the modul e.
I f CCd i s di spl ayed, check the CCD and Body Con-
trol Modul e (BCM) for proper operati on, refer to the
appropri ate di agnosti c test procedures manual I f the
CCD and the BCM are OK, repl ace the CMTC mod-
ul e.
For addi ti onal di agnosti c i nformati on on the CMTC
and for i denti fyi ng CMTC probl ems, refer to the
proper Body Di agnosti c Procedures manual .
The Compass Mi ni -Tri p Computer (CMTC) system
i s l ocated i n the overhead consol e. CMTC consi sts of
a el ectroni c control modul e wi th a vacuum fl uores-
cent di spl ay (VFD) and functi on swi tches. The CMTC
consi sts of a el ectroni c modul e that di spl ays compass,
tri p computer, and temperature features. Actuati ng
the STEP swi tch wi l l cause the CMTC to change
mode of operati on when i gni ti on i s ON. Exampl e:
Compass/Temperature
Tri p odometer (ODO)
Average mi l es per gal l on (ECO)
I nstant mi l es per gal l on (ECO)
Di stance to empty (DTE)
El apsed ti me (ET)
Off
The CMTC modul e i n the overhead consol e has
three buttons used to sel ect vari ous functi ons. The
CMTC sel ector buttons wi l l not operate unti l the
i gni ti on i s i n the RUN posi ti on (Fi g. 1).
When the i gni ti on swi tch i s fi rst turned to the
RUN posi ti on the CMTC di spl ay;
Bl anks momentari l y
Al l segments of the VFD wi l l l i ght for one sec-
ond
Bl anks momentari l y
Returns to the l ast mode setti ng sel ected before
the i gni ti on was l ast swi tched OFF.
NS OVERHEAD CONSOLE 8V - 1
THERMOMETER AND COMPASS
THERMOMETER
Engi ne temperature can i ncrease the di spl ayed
temperature. The CMTC i s desi gned to dampen tem-
perature readi ngs when the vehi cl e i s movi ng at a
rate sl ower than 18 mi l es per hour.
The outsi de temperature i s measured from a sen-
sor mounted i n the front of the vehi cl e. I f the tem-
perature i s more than 55C (131F) or the
temperature sendi ng l i ne i s shorted to ground, the
temperature di spl ay shoul d read SC. I f the tempera-
ture i s l ess than -40C (-40F), or the sendi ng l i ne i s
an open ci rcui t, the di spl ay shoul d read OC.
The CMTC wi l l not al l ow the temperature readi ng
to i ncrease when the vehi cl e i s not movi ng.
COMPASS
The CMTC i s sel f cal i brati ng and usual l y requi res
no adjustment. The compass wi l l conti nuousl y per-
form a sl ow cal i brati on to compensate for smal l mag-
neti c vari ati ons common to any automobi l e.
Uncommon magneti c shi fts may be caused by i tems
such as magneti c base antennas, whi ch can perma-
nentl y al ter the magneti c fi el d of the vehi cl e roof
panel . I f excessi ve magneti c fi el d conti nues for 5 mi n-
utes, the compass headi ng wi l l go bl ank and onl y the
CAL symbol wi l l i l l umi nate. When thi s occurs, the
vehi cl e roof panel may requi re demagneti zi ng. Refer
to the demagneti zi ng procedure i n thi s secti on.
Moderate magneti c shi fts may, on very rare occa-
si ons, cause the compass headi ng to di spl ay onl y one
or two of the ei ght possi bl e headi ngs. Al though the
compass wi l l eventual l y compensate for thi s shi ft, i t
coul d take several i gni ti on cycl es. The compensati on
process can be expedi ted by manual l y acti vati ng the
fast cal i brati on routi ne. Refer to the fast cal i brati ng
procedure i n thi s secti on. Thi s procedure may be per-
formed anyti me that the compass appears to be i nac-
curate.
I f the cal i brati on data stored i n the body control
modul e i s not recei ved, the compass wi l l read onl y
NE North-East. The CMTC i s sel f cal i brati ng and
requi res no adjusti ng. The word CAL i s di spl ayed to
show that the compass i s i n cal i brati on mode. CAL
wi l l turn off after the vehi cl e has gone through three
compl ete ci rcl es wi thout stoppi ng, i n an area free of
magneti c di sturbance. I f modul e di spl ays tempera-
ture whi l e the compass i s bl ank, turn off i gni ti on and
run sel f di agnosti cs then demagneti ze the vehi cl e.
After demagneti zi ng, check compass cal i brati on num-
ber, refer to Sel f Di agnosti c Test. I f greater than 15,
demagneti ze agai n unti l readi ng i s l ess than 15. I f
compass sti l l goes bl ank after demagneti zi ng then
check i nternal di agnosti cs and demagneti ze.
UNIVERSAL TRANSMITTER
The Uni versal Transmi tter, repl aces the hand hel d
remote control s that open the garage door, motori zed
gates, or home l i ghti ng i n/outsi de the home. Thi s
devi ce memori zes the acti vator codes for up to three
remote control l ed devi ces. I t tri ggers those devi ces at
the push of a button, l ocated i n a uni t permanentl y
mounted i n your overhead consol e (i f equi pped).
The transmi tter operates off your vehi cl es battery
and chargi ng system; no batteri es are needed.
The Uni versal Transmi tter i ncorporates a Rol l i ng
Code technol ogy (random di gi tal code si gnal s from
the remote transmi tter) wi thi n the transmi tter mod-
ul e. Thi s i s done so, as an added securi ty measure.
Features of the Uni versal Transmi tter are:
Can be used wi th most other Radi o Frequency
(RF) acti vated devi ces.
I ndi vi dual channel s can be trai ned.
Fig. 1 Compass Mini-Trip Computer (CMTC)
Switches and Display
Fig. 2 Universal Transmitter Location
8V - 2 OVERHEAD CONSOLE NS
Stores transmi tter data i n permanent memory -
retrai ni ng i s not requi red even i f the battery di es or
i s di sconnected.
To operate, si mpl y press the appropri ate button on
the Uni versal Transmi tter. The red LED wi l l l i ght up
whi l e the si gnal i s bei ng transmi tted.
NOTE: For security reasons, you are able to erase
the trained frequencies.
READING/DOME LAMP DIAGNOSIS
The dome l amps operate i n conjuncti on wi th the
Remote Keyl ess Entry system. Refer to the Wi ri ng
Di agrams group of thi s manual for component l oca-
ti ons and ci rcui t i nformati on. For addi ti onal di agnos-
ti c i nformati on on l amp operati on control l ed by Body
Control Modul e (BCM) refer to the Body Di agnosti c
Procedures Manual . For di agnosi s of the readi ng
l amps and swi tches refer to (Fi g. 3).
TRAVELER MESSAGES
Travel er data i s obtai ned from the Body Control
Modul e (BCM) on the CCD bus wi res. The CMTC
wi l l not di spl ay i nformati on for any of the screens for
whi ch i t di d not recei ve the bus messages. The l abel
correspondi ng to the mi ssi ng i nformati on wi l l be l i t.
I f no travel er data i s di spl ayed, check the CCD com-
muni cati ons and the BCM. I f the bri ghtness l evel i s
i mproper check the CCD bus. One general method
for checki ng the CCD bus communi cati ons between
CMTC and the BCM i s refer to the fol l owi ng proce-
dure.
(1) STEP the CMTC to the El apsed Ti me (ET).
(2) Press and rel ease the reset button to reset the
modul e.
(3) I f the el apsed ti me cl ock does not reset, or fai l s
to update, check the CCD wi res and the BCM. The
DRB i s recommended for checki ng the CCD and the
BCM.
(4) Perform the CMTC sel f di agnosi s before repl ac-
i ng the modul e.
Before proceedi ng i n di agnosi s, check the transmi t-
ter for battery vol tage and a good ground at the
transmi tter harness connector.
The uni t may not have been trai ned correctl y,
try retrai ni ng the transmi tter.
The batteri es i n the hand-hel d transmi tter may
be dead.
Fig. 3 Reading/Dome Lamp Diagnosis
Rotate your hand-hel d transmi tter end-over-end
and trai n agai n. For best resul ts, pl ace the end oppo-
si te from the battery compartment agai nst the uni -
versal transmi tter whi l e trai ni ng.
The frequency of the hand-hel d transmi tter may
not be i n the desi red frequenci es between 286MHz
and 399MHz set by FCC.
SERVICE PROCEDURES
COMPASS CALIBRATION PROCEDURE
Vari ance i s the di fference between magneti c North
and geographi c North (Fi g. 4). To adjust the compass
vari ance set the CMTC to Compass/Temperature
mode and press RESET buttons for 5 seconds. The
symbol VAR and the current vari ance zone number
wi l l be di spl ayed. Press the STEP button to sel ect
the proper vari ance zone as shown i n (Fi g. 4). Press
the US/Metri c button to save the new vari ance zone
and normal CMTC operati on. I f both buttons are
hel d for 10 seconds i nstead 5 seconds the CMTC wi l l
set vari ance to 8 and enter the fast cal i brati on mode.
COMPASS CALIBRATION PROCEDURE (FAST
METHOD)
When the compass i s subjected to excessi ve mag-
neti c fi el ds, the CMTC automati cal l y enters a fast
cal i brati on mode where i s tri es to compensate for the
l arge magneti c shi fts.
I f the compass i s i naccurate, appears to be i naccu-
rate and the CAL i s not i l l umi nated the fast cal i bra-
ti on mode may be manual l y entered by usi ng the
fol l owi ng procedure.
(1) Set the CMTC to Compass/Temperature mode
and press the reset button for 10 conti nuous seconds.
Manual acti vati on of the fast cal i brati on i s general l y
not requi red.
(2) Compass vari ance sets to the defaul t of 8 after
the fast cal i brati on i s manual l y acti vated.
(3) Compl ete the compass vari ance setti ng proce-
dure by referri ng to the Compass Vari ance Procedure
i n thi s secti on
(4) Dri ve the vehi cl e i n three 360 turns i n an area
free from l arge metal objects. I f the CAL symbol
remai ns l i t after compl eti ng thi s step, the roof panel
may need demagneti zi ng
DEMAGNETIZING PROCEDURE
A magneti c fi el d can adversel y affect the compass.
Magneti c i nterference can magneti ze the roof panel .
Magneti zi ng can be caused by pl aci ng a permanent
magnet i n contact wi th the roof panel . Exampl e:
Magneti c Base Antenna
Magneti c screwdri ver
Audi o speakers
Refri gerator magnets.
Pi zza Si gns
Bubbl e gum fl asher l i ghts
Fig. 4 Variance Settings
Removi ng magneti c i nterferi ng objects wi l l usual l y
restore normal compass operati on. I f the compass
di spl ay remai ns bl ank whi l e the CAL l abel i s i l l umi -
nated, then the roof panel requi res demagneti zi ng. To
demagneti ze use Speci al Tool 6029 for demagneti zi ng
the roof panel . The demagneti zi ng procedure wi l l
demagneti ze the roof and mounti ng screws i n the
overhead consol e. I t i s i mportant that you fol l ow the
i nstructi ons bel ow exactl y. The mounti ng screws and
the mounti ng brackets around the compass area are
steel , and therefore ai d i n the demagneti zi ng of the
roof panel .
(1) Be sure the i gni ti on swi tch i s i n the OFF posi -
ti on before you begi n the demagneti ze procedure.
(2) Pl ug the demagneti zi ng tool i nto a standard
110/115 vol t AC outl et, keepi ng the demagneti zi ng
tool at l east 12 i nches away from the compass area
when pl uggi ng i t i n.
(3) Sl owl y approach and contact the consol e
mounti ng screw wi th the pl asti c coated ti p of the tool
for at l east two seconds.
(4) Wi th the demagneti zi ng tool sti l l energi zed,
sl owl y back i t away from the screw unti l the ti p i s at
l east 12 i nches from the screw head.
(5) Repeat the l ast step wi th al l the consol e
mounti ng screws.
(6) After you have pul l ed at l east 12 i nches from
the l ast screw, remove the demagneti zi ng tool from
i nsi de vehi cl e and di sconnect i t from the el ectri cal
outl et.
(7) Pl ace an 8 1/2 X 11 i nch pi ece of paper l ength-
wi se on the roof of vehi cl e di rectl y above compass.
The purpose of the paper i s to protect the roof panel
from scratches and defi ne the area to be demagne-
ti zed.
(8) Pl ug i n the demagneti zi ng tool , keepi ng i t at
l east two feet away from the compass uni t.
(9) Sl owl y approach the center of the roof panel at
the wi ndshi el d wi th the demagneti zi ng tool pl ugged
i n.
(10) Contact the roof panel wi th the ti p of the tool .
Usi ng sl ow sweepi ng moti ons of 1/2 i nch between
sweeps. Move the tool approxi matel y four i nches
ei ther si de of the center l i ne and at l east 11 i nches
back from the wi ndshi el d.
(11) Wi th the demagneti zi ng tool sti l l energi zed,
sl owl y back away from the roof panel unti l the ti p i s
at l east two feet from the roof before unpl uggi ng the
tool .
(12) Recal i brate compass, refer to the compass cal -
i brati on procedure i n thi s secti on.
TRAINING
(1) Turn off the engi ne.
(2) Erase the factory test codes by pressi ng the
two outsi de buttons. Rel ease the buttons when the
red l i ght begi ns to fl ash (about 20 seconds).
(3) Choose one of the three buttons to trai n. Pl ace
the hand-hel d transmi tter wi thi n one i nch of the uni -
versal transmi tter and push the buttons on both
transmi tters. The red l i ght on the uni versal trans-
mi tter wi l l begi n to fl ash sl owl y.
(4) When the red l i ght on the uni versal transmi t-
ter begi ns to fl ash rapi dl y (thi s may take as l ong as
60 seconds), rel ease both buttons. Your uni versal
transmi tter i s now trai ned. To trai n the other but-
tons, repeat Step 3 and Step 4. Be sure to keep your
hand-hel d transmi tter i n case you need to retrai n the
uni versal transmi tter.
ERASING
To erase the uni versal transmi tter codes, si mpl y
hol d down the two outsi de buttons unti l the red LED
begi ns to fl ash.
NOTE: Individual channels cannot be erased. Eras-
ing the transmitter codes will erase ALL pro-
grammed codes.
AMBIENT TEMPERATURE SENSOR
REMOVAL
(1) Rai se and support vehi cl e on safety stands.
(2) From behi nd front bumper fasci a, remove
screw hol di ng sensor to radi ator cl osure panel .
(3) Remove sensor from vehi cl e.
INSTALLATION
Fig. 5 Universal Transmitter
MODULE
REMOVAL
(2) Remove overhead consol e.
(3) Remove the si x screws hol di ng CMTC modul e
to overhead consol e (Fi g. 6).
(4) Remove CMTC modul e from consol e.
INSTALLATION
COMPASS MINI-TRIP COMPUTER (CMTC) LAMP
BULBS
REMOVAL
ter turn (Fi g. 7).
(3) Pul l bul b socket from CMTC modul e.
INSTALLATION
FRONT HEADER READING/COURTESY LAMP
REMOVAL
(1) Pl ace a smal l fl at tool i n the sl ot at the forward
edge of the l amp l ens and twi st (Fi g. 8).
(2) Remove l ens.
(3) I nsert the ti p of the tool under the i nsi de, rear
edge of the refl ector/l i ght shi el d. Careful l y pry refl ec-
tor/l i ght shi el d out.
(4) Remove the l amp by pressi ng forward the brass
termi nal and rotati ng the l amp cl ockwi se to remove.
INSTALLATION
When i nstal l i ng the l amp l ens, fi rst gui de the swi tch
contact tab on the l ens between the l amp swi tch
pl unger and the l amp bezel . Then snap l ens onto the
two l ens pi vots on the bezel .
OVERHEAD CONSOLE
REMOVAL
(1) Open the transmi tter bi n door (Fi g. 9).
(2) Remove screw hol di ng the overhead consol e to
the headl i ner. Wi th the screw removed the consol e i s
retai ned by one engagement tab l ocated i nsi de the
eyegl ass storage bi n.
(3) Open the eyegl ass bi n door.
(4) Press the retai ni ng tab whi ch i s l ocated
di rectl y above the door l atch.
(5) Lower rear of consol e away from headl i ner.
(6) Pul l consol e rearward to di sengage cl i ps hol d-
i ng front of consol e to roof armature and l ower con-
sol e.
(7) Di sconnect wi re connectors from back of CMTC
and readi ng l amps. Ensure the connectors l ock tabs
are ful l y depressed before di sconnecti ng.
INSTALLATION
READING/COURTESY LAMP
Removal
(1) Usi ng a tri m sti ck, l i ghtl y pry outward the for-
ward end of readi ng l amp l ens (Fi g. 10).
(2) Rotate readi ng/courtesy l amp socket one quar-
ter turn countercl ockwi se.
(3) Pul l socket out of l amp (Fi g. 11).
(4) Pul l l amp from socket.
Fig. 6 Compass Mini-Trip Computer
Fig. 7 CMTC Lamp Bulbs
Installation
When i nstal l i ng the l amp l ens, fi rst gui de the swi tch
contact tab on the l ens between the l amp swi tch
pl unger and the l amp bezel . Then snap l ens onto the
two l ens pi vots on the bezel .
READING/COURTESY LAMP ASSEMBLY
Removal
(2) Remove the overhead consol e.
(3) Remove the screws hol di ng the readi ng l amp to
the overhead consol e (Fi g. 12).
(4) Remove the l amp from the overhead consol e.
(5) Di sconnect the wi re connectors from the back
of the readi ng l amp (Fi g. 13).
(6) Di sconnect the readi ng l amp swi tch from the
keyhol e sl ot i n the readi ng l amp.
(7) Remove the readi ng l amp from the overhead
consol e.
Installation
REMOVAL
The Uni versal Transmi tter i s servi ced wi th the
transmi tter bi n door, i n the overhead consol e.
Fig. 8 Lamp and Lens Removal
(1) Di sconnect and i sol ate negati ve battery cabl e.
(2) Open transmi tter bi n door i n rear of overhead
consol e.
(3) Gentl y pul l towards rear of vehi cl e, rel easi ng
transmi tter bi n door.
(4) Di sconnect harness connector from Uni versal
Transmi tter and remove bi n door from vehi cl e.
INSTALLATION
For i nstal l ati on, reverse the above procedures. The
Uni versal Transmi tter wi l l need to be retrai ned.
Refer to SERVI CE PROCEDURES i n thi s secti on.
Fig. 9 Overhead Console
Fig. 10 Reading/Courtesy lamp lens
Fig. 11 Socket and Lamp
Fig. 12 Reading/Courtesy Lamp
Fig. 13 Connector and Switch
SPECIAL TOOLS
SPECIAL TOOL
Degausser 6029
WIRING DIAGRAMS
CONTENTS
page page
AIR CONDITIONING-HEATER . . . . . . . . . . 8W-42-1
AIRBAG SYSTEM . . . . . . . . . . . . . . . . . . . 8W-43-1
ANTI-LOCK BRAKES . . . . . . . . . . . . . . . . . 8W-35-1
AUDIO SYSTEM . . . . . . . . . . . . . . . . . . . . 8W-47-1
BODY CONTROL MODULE . . . . . . . . . . . . 8W-45-1
CHARGING SYSTEM . . . . . . . . . . . . . . . . . 8W-20-1
COMPONENT INDEX . . . . . . . . . . . . . . . . . 8W-02-1
CONNECTOR/GROUND LOCATIONS . . . . . 8W-90-1
CONNECTOR PIN-OUTS . . . . . . . . . . . . . . 8W-80-1
FRONT LIGHTING . . . . . . . . . . . . . . . . . . . 8W-50-1
FUEL/IGNITION SYSTEM . . . . . . . . . . . . . 8W-30-1
GENERAL INFORMATION . . . . . . . . . . . . . 8W-01-1
GROUND DISTRIBUTION . . . . . . . . . . . . . 8W-15-1
HORN/CIGAR LIGHTER/POWER OUTLET . 8W-41-1
INSTRUMENT CLUSTER . . . . . . . . . . . . . . 8W-40-1
INTERIOR LIGHTING . . . . . . . . . . . . . . . . . 8W-44-1
JUNCTION BLOCK . . . . . . . . . . . . . . . . . . . 8W-12-1
MESSAGE CENTER . . . . . . . . . . . . . . . . . . 8W-46-1
OVERHEAD CONSOLE . . . . . . . . . . . . . . . . 8W-49-1
POWER DISTRIBUTION . . . . . . . . . . . . . . 8W-10-1
POWER DOOR LOCKS . . . . . . . . . . . . . . . 8W-61-1
POWER MIRRORS . . . . . . . . . . . . . . . . . . 8W-62-1
POWER SEAT . . . . . . . . . . . . . . . . . . . . . . 8W-63-1
POWER WINDOWS . . . . . . . . . . . . . . . . . . 8W-60-1
REAR LIGHTING . . . . . . . . . . . . . . . . . . . . 8W-51-1
SPLICE INFORMATION . . . . . . . . . . . . . . . 8W-70-1
SPLICE LOCATIONS . . . . . . . . . . . . . . . . . 8W-95-1
STARTING SYSTEM . . . . . . . . . . . . . . . . . 8W-21-1
TRAILER TOW . . . . . . . . . . . . . . . . . . . . . . 8W-54-1
TRANSMISSION CONTROL SYSTEM . . . . 8W-31-1
TURN SIGNALS . . . . . . . . . . . . . . . . . . . . . 8W-52-1
VEHICLE SPEED CONTROL . . . . . . . . . . . 8W-33-1
VEHICLE THEFT SECURITY SYSTEM . . . . 8W-39-1
WINDOW DEFOGGERS . . . . . . . . . . . . . . . 8W-48-1
WIPERS . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-53-1
NS/GS WIRING DIAGRAMS 8W - 1
8W-01 GENERAL INFORMATION
INDEX
page page
CIRCUIT FUNCTIONS . . . . . . . . . . . . . . . . . . . . . 4
CIRCUIT INFORMATION . . . . . . . . . . . . . . . . . . . 4
CONNECTOR INFORMATION . . . . . . . . . . . . . . . 7
ELECTROSTATIC DISCHARGE (ESD)
SENSITIVE DEVICES . . . . . . . . . . . . . . . . . . . . 8
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . 1
NOTES, CAUTIONS, and WARNINGS . . . . . . . . . 7
POSITIVE TEMPERATURE COEFFICIENT . . . . . . 8
SECTION IDENTIFICATION . . . . . . . . . . . . . . . . . 5
SPLICE LOCATIONS . . . . . . . . . . . . . . . . . . . . . . 7
SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
TAKE OUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
TERMINOLOGY . . . . . . . . . . . . . . . . . . . . . . . . . . 7
INTERMITTENT AND POOR CONNECTIONS . . . . 9
TROUBLESHOOTING TESTS . . . . . . . . . . . . . . . . 9
TROUBLESHOOTING TOOLS . . . . . . . . . . . . . . . 8
TROUBLESHOOTING WIRING PROBLEMS . . . . 10
SERVICE PROCEDURES
CONNECTOR AND TERMINAL REPLACEMENT . 12
CONNECTOR REPLACEMENT . . . . . . . . . . . . . . 11
DIODE REPLACEMENT . . . . . . . . . . . . . . . . . . . 14
TERMINAL REPLACEMENT . . . . . . . . . . . . . . . . 13
TERMINAL/CONNECTOR REPAIR- AUGAT
CONNECTORS . . . . . . . . . . . . . . . . . . . . . . . . 12
TERMINAL/CONNECTOR REPAIR-MOLEX
CONNECTORS . . . . . . . . . . . . . . . . . . . . . . . . 11
WIRING REPAIR . . . . . . . . . . . . . . . . . . . . . . . . 10
SPECIAL TOOLS
WIRING/TERMINAL . . . . . . . . . . . . . . . . . . . . . . 14
INTRODUCTION
Chrysl er wi ri ng di agrams are desi gned to provi de
i nformati on regardi ng the vehi cl es wi ri ng content. I n
order to effecti vel y use Chrysl er wi ri ng di agrams to
di agnose and repai r a Chrysl er vehi cl e, i t i s i mpor-
tant to understand al l of thei r features and charac-
teri sti cs.
Di agrams are arranged such that the power (B+)
si de of the ci rcui t i s pl aced near the top of the page,
and the ground (B-) si de of the ci rcui t i s pl aced near
the bottom of the page.
Al l swi tches, components, and modul es are shown
i n the at rest posi ti on wi th the doors cl osed and the
key removed from the i gni ti on.
Components are shown two ways. A sol i d l i ne
around a component i ndi cates that the component i s
compl ete. A dashed l i ne around a component i ndi -
cates that the component bei ng shown i s not com-
pl ete. I ncompl ete components have a reference
number to i ndi cate the page where the component i s
shown compl ete.
I t i s i mportant to real i ze that no attempt i s made
on the di agrams to represent components and wi ri ng
as they appear on the vehi cl e. For exampl e, a short
pi ece of wi re i s treated the same as a l ong one. I n
addi ti on, swi tches and other components are shown
as si mpl y as possi bl e, wi th regard to functi on onl y.
NS/GS 8W-01 GENERAL INFORMATION 8W - 01 - 1
8W - 01 - 2 8W-01 GENERAL INFORMATION NS/GS
CIRCUIT INFORMATION
Each wi re shown i n the di agrams contai ns a code
whi ch i denti fi es the mai n ci rcui t, part of the mai n
ci rcui t, gage of wi re, and col or (Fi g. 1).
CIRCUIT FUNCTIONS
Al l ci rcui ts i n the di agrams use an al pha/numeri c
code to i denti fy the wi re and i ts functi on. To i denti fy
whi ch ci rcui t code appl i es to a system, refer to the
Ci rcui t I denti fi cati on Code Chart. Thi s chart shows
the mai n ci rcui ts onl y and does not show the second-
ary codes that may appl y to some model s.
Fig. 1 Wire Code Identification
COLOR CODE COLOR
STANDARD
TRACER
COLOR
BL BLUE WT
BK BLACK WT
BR BROWN WT
DB DARK BLUE WT
DG DARK GREEN WT
GY GRAY BK
LB LIGHT BLUE BK
LG LIGHT GREEN BK
OR ORANGE BK
PK PINK BK or WT
RD RED WT
TN TAN WT
VT VIOLET WT
WT WHITE BK
YL YELLOW BK
* WITH TRACER
CIRCUIT FUNCTION
A BATTERY FEED
B BRAKE CONTROLS
C CLIMATE CONTROLS
D DIAGNOSTIC CIRCUITS
E DIMMING ILLUMINATION CIRCUITS
F FUSED CIRCUITS
G MONITORING CIRCUITS (GAUGES)
H OPEN
I NOT USED
J OPEN
K POWERTRAIN CONTROL MODULE
L EXTERIOR LIGHTING
M INTERIOR LIGHTING
N NOT USED
O NOT USED
P POWER OPTION (BATTERY FEED)
Q POWER OPTIONS (IGNITION FEED)
R PASSIVE RESTRAINT
S SUSPENSION/STEERING
T TRANSMISSION/TRANSAXLE/
TRANSFER CASE
U OPEN
V SPEED CONTROL, WIPER/WASHER
W OPEN
X AUDIO SYSTEMS
Y OPEN
Z GROUNDS
SECTION IDENTIFICATION
The wi ri ng di agrams are grouped i nto i ndi vi dual
secti ons. I f a component i s most l i kel y found i n a par-
ti cul ar group, i t wi l l be shown compl ete (al l wi res,
connectors, and pi ns) wi thi n that group. For exam-
pl e, the Auto Shutdown Rel ay i s most l i kel y to be
found i n Group 30, so i t i s shown there compl ete. I t
can, however, be shown parti al l y i n another group i f
i t contai ns some associ ated wi ri ng.
SYMBOLS
I nternati onal symbol s are used throughout the wi r-
i ng di agrams. These symbol s are consi stent wi th
those bei ng used around the worl d.
GROUP TOPIC
8W-01 thru 8W-09 General Information and
Diagram Overview
8W-10 thru 8W-19 Main Sources of Power and
Vehicle Grounding
8W-20 thru 8W-29 Starting and Charging
8W-30 thru 8W-39 Powertrain/Drivetrain
Systems
8W-40 thru 8W-49 Body Electrical items and A/C
8W-50 thru 8W-59 Exterior Lighting, Wipers, and
Trailer Tow
8W-60 thru 8W-69 Power Accessories
8W-70 Splice Information
8W-80 Connector Pin Outs
8W-90 Connector Locations
(including grounds)
8W-95 Splice Locations
Wiring Diagram Symbols
TERMINOLOGY
Thi s a l i st of terms wi th there defi ni ti ons used i n
the wi ri ng di agrams.
Bui l t-Up-Export . . . . . . . . .Vehi cl es Bui l t For Sal e I n
Markets Other Than North Ameri ca
Except-Bui l t-Up-Export . . . . .Vehi cl es Bui l t For Sal e
I n North Ameri ca
LHD . . . . . . . . . . . . . . . . . .Left Hand Dri ve Vehi cl es
RHD . . . . . . . . . . . . . . . . .Ri ght Hand Dri ve Vehi cl es
ATX . . . .Automati c Transmi ssi on-Front Wheel Dri ve
MTX. . . . . .Manual Transmi ssi on-Front Wheel Dri ve
AT. . . . . .Automati c Transmi ssi on-Rear Wheel Dri ve
MT . . . . . . .Manual Transmi ssi on-Rear Wheel Dri ve
SOHC. . . . . . . . . . . . .Si ngl e Over Head Cam Engi ne
DOHC . . . . . . . . . . . . .Dual Over Head Cam Engi ne
CONNECTOR INFORMATION
CAUTION: Not all connectors are serviced. Some
connectors are serviced only with a harness. A typ-
ical example might be the Supplemental Restraint
System connectors. Always check parts availability
before attempting a repair.
IDENTIFICATION
I n-l i ne connectors are i denti fi ed by a number, as
fol l ows:
I n-l i ne connectors l ocated on the engine com-
partment harness are C100 seri es numbers.
Connectors l ocated on the instrument panel
harness are C200 seri es numbers.
Connectors l ocated on the body harness are
C300 seri es numbers.
J umper harness connectors are C400 seri es
numbers.
Grounds and ground connectors are i denti -
fi ed wi th a G and fol l ow the same seri es number-
i ng as the i n-l i ne connector.
Component connectors are i denti fi ed by the compo-
nent name i nstead of a number (Fi g. 2). Mul ti pl e
connectors on a component use a C1, C2, etc. i denti -
fi er (Fi g. 3).
LOCATIONS
Secti on 8W-90 contai ns connector/ground l ocati on
i l l ustrati ons. The i l l ustrati ons contai n the connector
name (or number)/ground number and component
i denti fi cati on. Connector/ground l ocati on charts i n
Secti on 8W-90 reference the i l l ustrati on number for
components and connectors.
Secti on 8W-80 shows each connector and the ci r-
cui ts i nvol ved wi th that connector. The connectors
are i denti fi ed usi ng the name/number on the Di a-
gram pages.
SPLICE LOCATIONS
Spl i ce Locati on charts i n Secti on 8W-70 show the
enti re spl i ce, and provi de references to other secti ons
the spl i ce serves.
Secti on 8W-95 contai ns i l l ustrati ons that show the
general l ocati on of the spl i ces i n each harness. The
i l l ustrati ons show the spl i ce by number, and provi de
a wri tten l ocati on.
NOTES, CAUTIONS, and WARNINGS
Throughout thi s group addi ti onal i mportant i nfor-
mati on i s presented i n three ways; Notes, Cauti ons,
and Warni ngs.
NOTES are used to hel p descri be how swi tches or
components operate to compl ete a parti cul ar ci rcui t.
They are al so used to i ndi cate di fferent condi ti ons
that may appear on the vehi cl e. For exampl e, an
up-to and after condi ti on.
CAUTIONS are used to i ndi cate i nformati on that
coul d prevent maki ng an error that may damage the
vehi cl e.
WARNINGS provi de i nformati on to prevent per-
sonal i njury and vehi cl e damage. Bel ow i s a l i st of
general warni ngs that shoul d be fol l owed any ti me a
vehi cl e i s bei ng servi ced.
WARNING: ALWAYS WEAR SAFETY GLASSES FOR
EYE PROTECTION.
WARNING: USE SAFETY STANDS ANYTIME A PRO-
CEDURE REQUIRES BEING UNDER A VEHICLE.
Fig. 2 Component Identification
Fig. 3 Connector Identification
WARNING: BE SURE THAT THE IGNITION SWITCH
ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
WARNING: SET THE PARKING BRAKE WHEN
WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL
TRANSMISSION SHOULD BE IN NEUTRAL.
WARNING: OPERATE THE ENGINE ONLY IN A
WELL-VENTILATED AREA.
WARNING: KEEP AWAY FROM MOVING PARTS
WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
WARNING: TO PREVENT SERIOUS BURNS, AVOID
CONTACT WITH HOT PARTS SUCH AS THE RADIA-
TOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATA-
LYTIC CONVERTER, AND MUFFLER.
WARNING: DO NOT ALLOW FLAME OR SPARKS
NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
WARNING: ALWAYS REMOVE RINGS, WATCHES,
LOOSE HANGING JEWELRY, AND LOOSE CLOTH-
ING.
TAKE OUTS
The abbrevi ati on T/O i s used i n the component
l ocati on secti on to i ndi cate a poi nt i n whi ch the wi r-
i ng harness branches out to a component.
ELECTROSTATIC DISCHARGE (ESD) SENSITIVE
DEVICES
Al l ESD sensi ti ve components are sol i d state and a
symbol (Fi g. 4) i s used to i ndi cate thi s. When han-
dl i ng any component wi th thi s symbol compl y wi th
the fol l owi ng procedures to reduce the possi bi l i ty of
el ectrostati c charge bui l d up on the body and i nad-
vertent di scharge i nto the component. I f i t i s not
known whether the part i s ESD sensi ti ve, assume
that i t i s.
(1) Al ways touch a known good ground before han-
dl i ng the part. Thi s shoul d be repeated whi l e han-
dl i ng the part and more frequentl y after sl i di ng
across a seat, si tti ng down from a standi ng posi ti on,
or wal ki ng a di stance.
(2) Avoi d touchi ng el ectri cal termi nal s of the part,
unl ess i nstructed to do so by a wri tten procedure.
(3) When usi ng a vol tmeter, be sure to connect the
ground l ead fi rst.
(4) Do not remove the part from i ts protecti ve
packi ng unti l i t i s ti me to i nstal l the part.
(5) Before removi ng the part from i ts package,
ground the package to a known good ground on the
vehi cl e.
POSITIVE TEMPERATURE COEFFICIENT
Posi ti ve Temperature Coeffi ci ent (PTC) devi ces are
bei ng used for ci rcui t protecti on. These PTCs act l i ke
a sol i d state fuse. They are l ocated i n the juncti on
bl ock, and are used to protect such i tems as: power
door l ock motors, power wi ndows, and vari ous engi ne
sol enoi ds.
A speci al symbol i s used to i denti fy these i n the
wi ri ng di agrams (Fi g. 5).
TROUBLESHOOTING TOOLS
When di agnosi ng a probl em i n an el ectri cal ci rcui t
there are several common tool s necessary. These tool s
are l i sted and expl ai ned bel ow.
Jumper Wi re - Thi s i s a test wi re used to con-
nect two poi nts of a ci rcui t. I t can be used to bypass
an open i n a ci rcui t.
WARNING: NEVER USE A JUMPER WIRE ACROSS
A LOAD, SUCH AS A MOTOR, CONNECTED
BETWEEN A BATTERY FEED AND GROUND.
Fig. 4 Electrostatic Discharge Symbol
Fig. 5 Positive Temperature Coefficient Symbol
Vol tmeter - Used to check for vol tage on a ci r-
cui t. Al ways connect the bl ack l ead to a known good
ground and the red l ead to the posi ti ve si de of the
ci rcui t.
CAUTION: Most of the electrical components used
in todays vehicle are solid state. When checking
voltages in these circuits use a meter with a 10-me-
gohm or greater impedance rating.
Ohmmeter - Used to check the resi stance
between two poi nts of a ci rcui t. Low or no resi stance
i n a ci rcui t means good conti nui ty.
CAUTION: - Most of the electrical components used
in todays vehicle are Solid State. When checking
resistance in these circuits use a meter with a 10-
megohm or greater impedance rating. In addition,
make sure the power is disconnected from the cir-
cuit. Circuits that are powered up by the vehicle
electrical system can cause damage to the equip-
ment and provide false readings.
Probi ng Tool s - These tool s are used for probi ng
termi nal s i n connectors (Fi g. 6). Sel ect the proper
si ze tool from Speci al Tool Package 6807, and i nsert
i t i nto the termi nal bei ng tested. Use the other end
of the tool to i nsert the meter probe.
INTERMITTENT AND POOR CONNECTIONS
Most i ntermi ttent el ectri cal probl ems are caused
by faul ty el ectri cal connecti ons or wi ri ng. I t i s al so
possi bl e for a sti cki ng component or rel ay to cause a
probl em. Before condemni ng a component or wi ri ng
assembl y check the fol l owi ng i tems.
Connectors are ful l y seated
Spread termi nal s, or termi nal push out
Termi nal s i n the wi ri ng assembl y are ful l y
seated i nto the connector/component and l ocked i n
posi ti on
Di rt or corrosi on on the termi nal s. Any amount
of corrosi on or di rt coul d cause an i ntermi ttent prob-
l em
Damaged connector/component casi ng exposi ng
the i tem to di rt and moi sture
Wi re i nsul ati on that has rubbed through causi ng
a short to ground
Some or al l of the wi ri ng strands broken i nsi de
of the i nsul ati on coveri ng.
Wi ri ng broken i nsi de of the i nsul ati on
TROUBLESHOOTING TESTS
Before begi nni ng any tests on a vehi cl es el ectri cal
system use the Wi ri ng Di agrams and study the ci r-
cui t. Al so refer to the Troubl eshooti ng Wi ri ng Prob-
l ems i n thi s secti on.
TESTING FOR VOLTAGE POTENTIAL
(1) Connect the ground l ead of a vol tmeter to a
known good ground (Fi g. 7).
(2) Connect the other l ead of the vol tmeter to the
sel ected test poi nt. The vehi cl e i gni ti on may need to
be turned ON to check vol tage. Refer to the appropri -
ate test procedure.
TESTING FOR CONTINUITY
(1) Remove the fuse for the ci rcui t bei ng checked
or, di sconnect the battery.
(2) Connect one l ead of the ohmmeter to one si de
of the ci rcui t bei ng tested (Fi g. 8).
(3) Connect the other l ead to the other end of the
ci rcui t bei ng tested. Low or no resi stance means good
conti nui ty.
TESTING FOR A SHORT TO GROUND
(1) Remove the fuse and di sconnect al l i tems
i nvol ved wi th the fuse.
(2) Connect a test l i ght or a vol tmeter across the
termi nal s of the fuse.
Fig. 6 Probing Tool
Fig. 7 Testing for Voltage Potential
(3) Starti ng at the fuse bl ock, wi ggl e the wi ri ng
harness about si x to ei ght i nches apart and watch
the vol tmeter/test l amp.
(4) I f the vol tmeter regi sters vol tage or the test
l amp gl ows, there i s a short to ground i n that gen-
eral area of the wi ri ng harness.
TESTING FOR A SHORT TO GROUND ON
FUSES POWERING SEVERAL LOADS
(1) Refer to the wi ri ng di agrams and di sconnect or
i sol ate al l i tems on the suspected fused ci rcui ts.
(2) Repl ace the bl own fuse.
(3) Suppl y power to the fuse by turni ng ON the
i gni ti on swi tch or re-connecti ng the battery.
(4) Start connecti ng the i tems i n the fuse ci rcui t
one at a ti me. When the fuse bl ows the ci rcui t wi th
the short to ground has been i sol ated.
TESTING FOR A VOLTAGE DROP
(1) Connect the posi ti ve l ead of the vol tmeter to
the si de of the ci rcui t cl osest to the battery (Fi g. 9).
(2) Connect the other l ead of the vol tmeter to the
other si de of the swi tch or component.
(3) Operate the i tem.
(4) The vol tmeter wi l l show the di fference i n vol t-
age between the two poi nts.
TROUBLESHOOTING WIRING PROBLEMS
When troubl eshooti ng wi ri ng probl ems there are
si x steps whi ch can ai d i n the procedure. The steps
are l i sted and expl ai ned bel ow. Al ways check for non-
factory i tems added to the vehi cl e before doi ng any
di agnosi s. I f the vehi cl e i s equi pped wi th these i tems,
di sconnect them to veri fy these add-on i tems are not
the cause of the probl em.
(1) Veri fy the probl em.
(2) Veri fy any rel ated symptoms. Do thi s by per-
formi ng operati onal checks on components that are
i n the same ci rcui t. Refer to the wi ri ng di agrams.
(3) Anal yze the symptoms. Use the wi ri ng di a-
grams to determi ne what the ci rcui t i s doi ng, where
the probl em most l i kel y i s occurri ng and where the
di agnosi s wi l l conti nue.
(4) I sol ate the probl em area.
(5) Repai r the probl em.
(6) Veri fy proper operati on. For thi s step check for
proper operati on of al l i tems on the repai red ci rcui t.
Refer to the wi ri ng di agrams.
SERVICE PROCEDURES
WIRING REPAIR
When repl aci ng or repai ri ng a wi re, i t i s i mportant
that the correct gage be used as shown i n the wi ri ng
di agrams. The wi res must al so be hel d securel y i n
pl ace to prevent damage to the i nsul ati on.
(1) Di sconnect battery negati ve cabl e
(2) Remove 1 i nch of i nsul ati on from each end of
the wi re.
(3) Pl ace a pi ece of heat shri nk tubi ng over one
si de of the wi re. Make sure the tubi ng wi l l be l ong
enough to cover and seal the enti re repai r area.
(4) Spread the strands of the wi re apart on each
part of the exposed wi re (exampl e 1). (Fi g. 10)
Fig. 8 Testing for Continuity Fig. 9 Testing for Voltage Drop
(5) Push the two ends of wi re together unti l the
strands of wi re are cl ose to the i nsul ati on (exampl e
2) (Fi g. 10)
(6) Twi st the wi res together (exampl e 3) (Fi g. 10)
(7) Sol der the connecti on together usi ng rosi n core
type sol der onl y. Do not use acid core solder.
(8) Center the heat shri nk tubi ng over the joi nt,
and heat usi ng a heat gun. Heat the joi nt unti l the
tubi ng i s ti ghtl y seal ed and seal ant comes out of both
ends of the tubi ng.
(9) Secure the wi re to the exi sti ng ones to prevent
chafi ng or damage to the i nsul ati on
(10) Connect battery and test al l affected systems.
TERMINAL/CONNECTOR REPAIR-MOLEX
CONNECTORS
(2) Di sconnect the connector from i ts mati ng hal f/
component.
(3) I nsert the termi nal rel easi ng speci al tool 6742
i nto the termi nal end of the connector (Fi g. 11).
(4) Usi ng speci al tool 6742 rel ease the l ocki ng fi n-
gers on the termi nal (Fi g. 12).
(5) Pul l on the wi re to remove i t from the connec-
tor.
(6) Repai r or repl ace the connector or termi nal , as
necessary.
CONNECTOR REPLACEMENT
(2) Di sconnect the connector that i s to be repai red
from i ts mati ng hal f/component
(3) Remove the connector l ocki ng wedge, i f
requi red (Fi g. 13)
(4) Posi ti on the connector l ocki ng fi nger away from
the termi nal usi ng the proper pi ck from speci al tool
Fig. 10 Wire Repair
Fig. 11 Molex Connector Repair
Fig. 12 Using Special Tool 6742
Fig. 13 Connector Locking Wedge
ki t 6680. Pul l on the wi re to remove the termi nal
from the connector (Fi g. 14) (Fi g. 15).
(5) Reset the termi nal l ocki ng tang, i f i t has one.
(6) I nsert the removed wi re i n the same cavi ty on
the repai r connector.
(7) Repeat steps four through si x for each wi re i n
the connector, bei ng sure that al l wi res are i nserted
i nto the proper cavi ti es. For addi ti onal connector pi n-
out i denti fi cati on, refer to the wi ri ng di agrams.
(8) I nsert the connector l ocki ng wedge i nto the
repai red connector, i f requi red.
(9) Connect connector to i ts mati ng hal f/component.
(10) Connect battery and test al l affected systems.
CONNECTOR AND TERMINAL REPLACEMENT
(2) Di sconnect the connector (that i s to be
repai red) from i ts mati ng hal f/component.
(3) Cut off the exi sti ng wi re connector di rectl y
behi nd the i nsul ator. Remove si x i nches of tape from
the harness.
(4) Stagger cut al l wi res on the harness si de at
1/2 i nch i nterval s (Fi g. 16).
(5) Remove 1 i nch of i nsul ati on from each wi re on
the harness si de.
(6) Stagger cut the matchi ng wi res on the repai r
connector assembl y i n the opposi te order as was done
on the harness si de of the repai r. Al l ow extra l ength
for sol dered connecti ons. Check that the overal l
l ength i s the same as the ori gi nal (Fi g. 16).
(7) Remove 1 i nch of i nsul ati on from each wi re.
si de of the wi re. Be sure the tubi ng wi l l be l ong
part of the exposed wi res.
strands of wi re are cl ose to the i nsul ati on.
(11) Twi st the wi res together.
(12) Sol der the connecti on together usi ng rosi n
core type sol der onl y. Do not use acid core solder.
(13) Center the heat shri nk tubi ng over the joi nt
ends of the tubi ng
(14) Repeat steps 8 through 13 for each wi re.
(15) Re-tape the wi re harness starti ng 1-1/2 i nches
behi nd the connector and 2 i nches past the repai r.
(16) Re-connect the repai red connector.
(17) Connect the battery, and test al l affected sys-
tems.
TERMINAL/CONNECTOR REPAIR- AUGAT
CONNECTORS
(2) Di sconnect the connector from i ts mati ng hal f/
component.
(3) Push down on the yel l ow connector l ocki ng tab
to rel ease the termi nal s (Fi g. 17).
(4) Usi ng speci al tool 6932, push the termi nal to
remove i t from the connector (Fi g. 18).
Fig. 14 Terminal Removal
Fig. 15 Terminal Removal Using Special Tool
Fig. 16 Stagger Cutting Wires
(5) Repai r or repl ace the connector or termi nal as
necessary.
(6) When re-assembl i ng the connector, the l ocki ng
wedge must be pl aced i n the l ocked posi ti on to pre-
vent termi nal push out.
TERMINAL REPLACEMENT
(2) Di sconnect the connector bei ng repai red from
i ts mati ng hal f. Remove connector l ocki ng wedge, i f
requi red (Fi g. 19).
(3) Remove connector l ocki ng wedge, i f requi red
(Fi g. 19).
(4) Posi ti on the connector l ocki ng fi nger away from
the termi nal usi ng the proper pi ck from speci al tool
ki t 6680. Pul l on the wi re to remove the termi nal
from the connector (Fi g. 20) (Fi g. 21).
(5) Cut the wi re 6 i nches from the back of the con-
nector.
(6) Remove 1 i nch of i nsul ati on from the wi re on
the harness si de.
(7) Sel ect a wi re from the termi nal repai r assem-
bl y that best matches the col or wi re bei ng repai red.
(8) Cut the repai r wi re to the proper l ength and
remove 1 i nch of i nsul ati on.
Fig. 17 Augat Connector Repair
Fig. 18 Using Special Tool 6932
Fig. 19 Connector Locking Wedge Tab (Typical)
Fig. 20 Terminal Removal
Fig. 21 Terminal Removal Using Special Tool
si de of the wi re. Make sure the tubi ng wi l l be l ong
part of the exposed wi res.
strands of wi re are cl ose to the i nsul ati on.
(12) Twi st the wi res together.
(13) Sol der the connecti on together usi ng rosi n
core type sol der onl y. Do not use acid core solder.
(14) Center the heat shri nk tubi ng over the joi nt
ends of the tubi ng.
(15) I nsert the repai red wi re i nto the connector.
(16) I nstal l the connector l ocki ng wedge, i f
requi red, and reconnect the connector to i ts mati ng
hal f/component.
(17) Re-tape the wi re harness starti ng 1-1/2 i nches
behi nd the connector and 2 i nches past the repai r.
(18) Connect battery, and test al l affected systems.
DIODE REPLACEMENT
(1) Di sconnect the battery.
(2) Locate the di ode i n the harness, and remove
the protecti ve coveri ng.
(3) Remove the di ode from the harness, pay atten-
ti on to the current fl ow di recti on (Fi g. 22).
(4) Remove the i nsul ati on from the wi res i n the
harness. Onl y remove enough i nsul ati on to sol der i n
the new di ode.
(5) I nstal l the new di ode i n the harness, maki ng
sure current fl ow i s correct. I f necessary refer to the
appropri ate wi ri ng di agram for current fl ow.
(6) Sol der the connecti on together usi ng rosi n core
type sol der onl y. Do not use acid core solder.
(7) Tape the di ode to the harness usi ng el ectri cal
tape maki ng, sure the di ode i s compl etel y seal ed
from the el ements.
(8) Re-connect the battery, and test affected systems.
SPECIAL TOOLS
WIRING/TERMINAL
Fig. 22 Diode Identification
Probing Tool Package 6807
Terminal Pick 6680
Terminal Removing Tool 6932
Terminal Removing Tool 6934
8W-02 COMPONENT INDEX
Component Page
2-4 Pressure Swi tch . . . . . . . . . . . . . . . . . . . . .8W-31
2-4 Sol enoi d . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-31
A/C Compressor Cl utch . . . . . . . . . . . . . . . . . .8W-42
A/C Compressor Cl utch Rel ay. . . . . . . . . . .8W-10, 42
A/C Heater Control . . . . . . . . . . . . . . . . . . . . .8W-42
A/C On I ndi cator . . . . . . . . . . . . . . . . . . . . . . .8W-42
A/C Pressure Transducer . . . . . . . . . . . . . .8W-30, 42
A/C Swi tch . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-42
A/C Zone Door Actuator . . . . . . . . . . . . . . . . . .8W-42
ABS Warni ng Lamp . . . . . . . . . . . . . . . . . .8W-35, 46
Accel erator Pedal Posi ti on Sensor . . . . . . . . . .8W-30
Ai rbag Control Modul e . . . . . . . . . . . . . . . . . . .8W-43
Ai rbag I ndi cator Lamp . . . . . . . . . . . . . . . . . . .8W-43
Ai rbag Warni ng Lamp . . . . . . . . . . . . . . . . . . .8W-46
Al l Wheel Dri ve Sol enoi d . . . . . . . . . . . . . . . . .8W-31
Ambi ent Ai r Temperature Sensor . . . . . . . . . . .8W-49
Ash Recei ver Lamp . . . . . . . . . . . . . . . . . . . . .8W-44
Automati c Day/Ni ght Mi rror . . . . . . . . . . . . . .8W-44
Automati c Shut Down Rel ay. . . . . . . . . . . .8W-10, 30
Spl i ce I nformati on . . . . . . . . . . . . . . . . . . . . . .8W-70
Back-Up Lamp . . . . . . . . . . . . . . . . . . . . . . . . .8W-51
Back-Up Swi tch . . . . . . . . . . . . . . . . . . . . .8W-44, 51
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-20
Bl end Door Actuator . . . . . . . . . . . . . . . . . . . . .8W-42
Body Control Modul e . . . . . . . . . . . . . . . . . . . .8W-45
Brake Pressure Swi tch . . . . . . . . . . . . . . . . . . .8W-46
Brake Warni ng Lamp . . . . . . . . . . . . . . . . . . . .8W-46
Camshaft Posi ti on Sensor . . . . . . . . . . . . . . . .8W-30
Center Dome Lamp . . . . . . . . . . . . . . . . . . . . .8W-44
Center Hi gh Mounted Stop Lamp . . . . . . . . . .8W-51
Ci gar/Accessory Rel ay . . . . . . . . . . . . . . . . . . .8W-41
Cl ockspri ng . . . . . . .8W-10, 15, 30, 33, 39, 40, 41, 43
Cl uster I l l umi nati on Lamps . . . . . . . . . . . . . . .8W-40
Cl utch I nterl ock Swi tch . . . . . . . . . . . . . . .8W-12, 21
Cl utch I nterl ock Swi tch Jumper . . . . . .8W-12, 21, 31
Cl utch Swi tch . . . . . . . . . . . . . . . . . . . . . . .8W-30, 33
Combi nati on Fl asher/DRL Modul e . . . .8W-50, 51, 52
Combi nati on Rel ays . . . . . . . . . . . . . . . . . . . . .8W-54
Compass/Mi ni -Tri p Computer . . . . . . . . . . . . . .8W-49
Control Sl eeve Sensor. . . . . . . . . . . . . . . . . . . .8W-30
Control l er Anti -Lock Brake . . . . . . . . . . . . . . .8W-35
Courtesy Lamp Rel ay . . . . . . . . . . .8W-10, 12, 44, 50
Crank Case Heater . . . . . . . . . . . . . . . . . . . . . .8W-30
Crankshaft Posi ti on Sensor . . . . . . . . . . . . . . .8W-30
Crui se I ndi cator Lamp . . . . . . . . . . . . . . . . . . .8W-40
Data Li nk Connector . . . . . . . . . . . . . . . . . . . .8W-30
Di esel Power Rel ay . . . . . . . . . . . . . . . . . . .8W-10, 30
Dome Lamp Swi tch . . . . . . . . . . . . . . . . . . . . .8W-50
Door Ajar I ndi cator Lamp . . . . . . . . . . . . . . . .8W-40
Door Ajar Swi tches . . . . . . . . . . . . . . . .8W-39, 40, 44
Door Lock Rel ay . . . . . . . . . . . . . . . . . . . . . . . .8W-61
Speakers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-47
Component Page
Door Unl ock Rel ay . . . . . . . . . . . . . . . . . . . . . .8W-61
Oxygen Sensors . . . . . . . . . . . . . . . . . . . . . . . .8W-30
Door Ajar Swi tches . . . . . . . . . . . . .8W-39, 40, 44, 45
Door Arm/Di sarm Swi tches. . . . . . . . . . . . .8W-39, 61
Door Courtesy Lamps . . . . . . . . . . . . . . . . . . . .8W-44
Door Lock Motors . . . . . . . . . . . . . . . . . . . . . . .8W-61
Door Lock Swi tches . . . . . . . . . . . . . . . . . . . . .8W-61
Door Unl ock Rel ays . . . . . . . . . . . . . . . . . . . . .8W-61
Heated Seat Backs . . . . . . . . . . . . . . . . . . . . . .8W-63
Heated Seat Cushi ons . . . . . . . . . . . . . . . . . . .8W-63
Heated Seat Modul es . . . . . . . . . . . . . . . . . . . .8W-63
Heated Seat Swi tches. . . . . . . . . . . . . . . . . . . .8W-63
Power Mi rrors . . . . . . . . . . . . . . . . . . . . . . . . .8W-62
Power Seat Swi tches . . . . . . . . . . . . . . . . . . . .8W-63
Power Wi ndow Swi tches . . . . . . . . . . . . . . . . . .8W-60
Seat Motors . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-63
Wi ndow Motors . . . . . . . . . . . . . . . . . . . . . . . .8W-60
Radi ator Fans . . . . . . . . . . . . . . . . . . . . . . . . .8W-42
Dump Sol enoi d . . . . . . . . . . . . . . . . . . . . . . . . .8W-33
EGR Sol enoi d . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30
El ectri c Wi per De-I cer . . . . . . . . . . . . . . . . . . .8W-48
El ectroni c PRNDL I ndi cator . . . . . . . . . . . . . . .8W-40
Engi ne Cool ant Temperature Gauge. . . . . . . . .8W-40
Engi ne Cool ant Temperature Lamp . . . . . . . . .8W-46
Engi ne Cool ant Temperature Sensor . . . . . . . .8W-30
Engi ne Oi l Pressure Swi tch . . . . . . . . . . . . . . .8W-46
Engi ne Speed Sensor . . . . . . . . . . . . . . . . . . . .8W-30
Engi ne Starter Motor . . . . . . . . . . . . . . . . . . . .8W-21
Engi ne Starter Motor Rel ay . . . . . . . . . . . .8W-10, 21
Evap Leak Detecti on Pump . . . . . . . . . . . . . . .8W-30
Evap/Purge Sol enoi d . . . . . . . . . . . . . . . . . . . .8W-30
Evaporator Temperature Sensor . . . . . . . . . . . .8W-42
Express Down Modul e . . . . . . . . . . . . . . . . . . .8W-60
Fl exi bl e Fuel Sensor . . . . . . . . . . . . . . . . . . . . .8W-30
Fog Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-50
Fog Lamp Rel ay . . . . . . . . . . . . . . . . . . . . . . . .8W-50
Front Bl ower Motor . . . . . . . . . . . . . . . . . . . . .8W-42
Front Bl ower Motor Rel ay . . . . . . . . . . . . .8W-10, 42
Front Bl ower Motor Resi stor Bl ock . . . . . . . . .8W-42
Front Ci gar Li ghter/Power Outl et . . . . . . . . . .8W-41
Front Readi ng Lamp Defeat Swi tch . . . . . . . . .8W-44
Front Readi ng Lamps/Swi tch . . . . . . . . . . . . . .8W-44
Front Washer Motor . . . . . . . . . . . . . . . . . . . . .8W-53
Front Wi per Swi tch . . . . . . . . . . . . . . . . . . . . .8W-53
Fuel Gauge. . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-40
Fuel Heater . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30
Fuel Heater Rel ay . . . . . . . . . . . . . . . . . . .8W-10, 30
Fuel I njectors . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30
Fuel Pump Modul e . . . . . . . . . . . . . . . . . . . . . .8W-30
Fuel Pump Rel ay . . . . . . . . . . . . . . . . . . . .8W-10, 30
Fuel Quanti ty Actuator . . . . . . . . . . . . . . . . . .8W-30
Fuel Shutdown Sol enoi d. . . . . . . . . . . . . . . . . .8W-30
NS/GS 8W - 02 COMPONENT INDEX 8W - 02 - 1
Component Page
Fuel Tank Modul e . . . . . . . . . . . . . . . . . . .8W-30, 45
Fuel Temperature Sensor . . . . . . . . . . . . . . . . .8W-30
Fuel Ti mi ng Sol enoi d . . . . . . . . . . . . . . . . . . . .8W-30
Fuses (JB) . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12
Fuses (PDC) . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10
Fusi bl e Li nk . . . . . . . . . . . . . . . . . . . . .8W-20, 21, 63
Fusi bl e Li nk A0 . . . . . . . . . . . . . . . . . . . . . . . .8W-30
Fusi bl e Li nk A11 . . . . . . . . . . . . . . . . . . . . . . .8W-10
Fusi bl e Li nk A54 . . . . . . . . . . . . . . . . . . . . . . .8W-10
Grounds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15
Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-20
Gl ove Box Lamp . . . . . . . . . . . . . . . . . . . . . . . .8W-44
Gl ow Pl ug Lamp . . . . . . . . . . . . . . . . . . . . .8W-30, 46
Gl ow Pl ugs . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30
Gl ow Pl ug Rel ay . . . . . . . . . . . . . . . . . . . . . . . .8W-30
Headl amps . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-50
Headl amp Di mmer Swi tch . . . . . . . . . .8W-10, 46, 50
Headl amp Level i ng Motors . . . . . . . . . . . . . . .8W-50
Headl amp Swi tch . . . . . . . . . . . . . . . . . . . . . . .8W-50
Headl amp Washer . . . . . . . . . . . . . . . . . . . . . .8W-53
Hi gh Beam I ndi cator . . . . . . . . . . . . . . . . . . . .8W-46
Hi gh Beam Rel ay . . . . . . . . . . . . . . . . . . . .8W-10, 50
Headl amps . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-50
Horns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-41
Hood Ajar Swi tch . . . . . . . . . . . . . . . . . . . .8W-39, 44
Horn Rel ay . . . . . . . . . . . . . . . . . . . . . . . . .8W-39, 41
Horn Swi tch . . . . . . . . . . . . . . . . . . . . .8W-10, 39, 41
HVAC Control . . . . . . . . . . . . . . . . . . . . . . . . .8W-42
I dl e Ai r Control Motor . . . . . . . . . . . . . . . . . . .8W-30
I gni ti on Coi l Pack. . . . . . . . . . . . . . . . . . . . . . .8W-30
I gni ti on Swi tch . . . . . . . . . . . . . . . . . . . . . . . . .8W-10
I nstrument Cl uster . . . . . . . . . . . . . . . . . . . . .8W-40
I ntake Ai r Temperature Sensor . . . . . . . . . . . .8W-30
I ntake Ai r Temperature/Mani fol d Absol ute
Pressure Sensor . . . . . . . . . . . . . . . . . . . . . 8W-30
I nteri or Lamps On Swi tch . . . . . . . . . . . . . . . .8W-44
Juncti on Bl ock . . . . . . . . . . . . . . . . . . . . . . . . .8W-12
Key-I n Hal o Lamp . . . . . . . . . . . . . . . . . . . . . .8W-44
Knock Sensor . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30
Lamp Assembl i es . . . . . . . . . . . . . . . . . . . . . . .8W-51
Li cense Lamp . . . . . . . . . . . . . . . . . . . . . . . . . .8W-51
Li ftgate Ajar I ndi cator Lamp . . . . . . . . . . . . . .8W-40
Li ftgate Ajar Swi tch . . . . . . . . . . . . . . .8W-39, 40, 44
Li ftgate Arm/Di sarm Swi tch . . . . . . . . . . . .8W-39, 61
Li ftgate Fl ood Lamps . . . . . . . . . . . . . . . . . . . .8W-44
Li ftgate Lock Motor . . . . . . . . . . . . . . . . . . . . .8W-61
Low Beam Rel ay. . . . . . . . . . . . . . . . . . . . .8W-10, 50
Low Cool ant Level Swi tch . . . . . . . . . . . . . . . .8W-45
Low Fuel Warni ng I ndi cator Lamp. . . . . . . . . .8W-40
Low Oi l Pressure Lamp . . . . . . . . . . . . . . . . . .8W-46
Low Washer Fl ui d Level I ndi cator Lamp . . . . .8W-40
Low Washer Fl ui d Swi tch. . . . . . . . . . . . . . . . .8W-53
Low/Reverse Pressure Swi tch . . . . . . . . . . . . . .8W-31
Low/Reverse Sol enoi d . . . . . . . . . . . . . . . . . . . .8W-31
Component Page
Mani fol d Absol ute Pressure Sensor . . . . . . . . .8W-30
Memory Power Seat Swi tch . . . . . . . . . . . . . . .8W-63
Seat Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-63
Memory Seat/Mi rror Modul e . . . . . . . . . . .8W-62, 63
Memory Set Swi tch . . . . . . . . . . . . . . . . . .8W-62, 63
Message Center . . . . . . . . . . . . . . . . . . . . . . . .8W-46
Mi d Readi ng Lamps . . . . . . . . . . . . . . . . . . . . .8W-44
Mode Door Actuator . . . . . . . . . . . . . . . . . . . . .8W-42
Name Brand Speaker Rel ay . . . . . . . . . . . . . . .8W-47
Needl e Movement Sensor . . . . . . . . . . . . . . . . .8W-30
Odometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-40
Output Shaft Speed Sensor . . . . . . . . . . . . . . .8W-31
Overdri ve Pressure Swi tch . . . . . . . . . . . . . . . .8W-31
Overdri ve Sol enoi d . . . . . . . . . . . . . . . . . . . . . .8W-31
Overhead Consol e. . . . . . . . . . . . . . . . . . . . . . .8W-49
Park Brake Swi tch . . . . . . . . . . . . . . . . . . .8W-46, 50
Park Lamp Rel ay. . . . . . . . .8W-10, 12, 44, 50, 51, 54
Park/Turn Si gnal Lamps . . . . . . . . . . . . . . . . .8W-50
Ai rbag Squi bs . . . . . . . . . . . . . . . . . . . . . . . . . .8W-43
Power Di stri buti on Center . . . . . . . . . . . . . . . .8W-10
Power Fol di ng Mi rror Swi tch . . . . . . . . . . . . . .8W-62
Power Mi rror Fol d Rel ay . . . . . . . . . . . . . . . . .8W-62
Power Mi rror Swi tch . . . . . . . . . . . . . . . . . . . .8W-62
Power Mi rror Unfol d Rel ay . . . . . . . . . . . . . . .8W-62
Power Seat Ci rcui t Breaker . . . . . . . . . . . .8W-62, 63
Powertrai n Control Modul e . . . . . . . . . . . . . . .8W-30
PTCs (JB). . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12
Radi ator Fan Di sconnect . . . . . . . . . . . . . . . . .8W-42
Radi ator Fan Rel ays. . . . . . . . . . . . . . . . . . . . .8W-42
Radi o . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-47
Radi o Choke . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-47
Readi ng Lamps . . . . . . . . . . . . . . . . . . . . . . . .8W-44
Rear A/C Heater Uni t. . . . . . . . . . . . . . . . . . . .8W-42
Rear Bl ower Control Swi tches . . . . . . . . . . . . .8W-42
Rear Ci gar Li ghter/Power Outl et . . . . . . . . . . .8W-41
Rear Defogger On I ndi cator . . . . . . . . . . . . . . .8W-42
Rear Dome Lamp . . . . . . . . . . . . . . . . . . . . . . .8W-44
Rear Fog Lamp. . . . . . . . . . . . . . . . . . . . . . . . .8W-51
Rear Fog Lamp I ndi cator . . . . . . . . . . . . . . . . .8W-51
Rear Washer Motor . . . . . . . . . . . . . . . . . . . . .8W-53
Rear Washer Swi tch . . . . . . . . . . . . . . . . . .8W-42, 53
Rear Wi ndow Defogger . . . . . . . . . . . . . . . . . . .8W-48
Rear Wi ndow Defogger Rel ay . . . . . . . . . . . . . .8W-48
Rear Wi ndow Defogger Swi tch . . . . . . . . . .8W-42, 48
Rear Wi per Del ay On I ndi cator . . . . . . . . .8W-42, 53
Rear Wi per Del ay Swi tch . . . . . . . . . . . . . .8W-42, 53
Rear Wi per Motor . . . . . . . . . . . . . . . . . . . . . . .8W-53
Rear Wi per On I ndi cator . . . . . . . . . . . . . .8W-42, 53
Rear Wi per On Swi tch . . . . . . . . . . . . . . . .8W-42, 53
Reci rcul ate Mode I ndi cator . . . . . . . . . . . . . . . .8W-42
Reci rcul ate Mode Swi tch . . . . . . . . . . . . . . . . .8W-42
Reci rcul ati on Door Actuator . . . . . . . . . . . . . . .8W-42
Remote Keyl ess Entry Modul e . . . . . . . . . . . . .8W-61
Repeater Lamps . . . . . . . . . . . . . . . . . . . . .8W-51, 52
8W - 02 - 2 8W - 02 COMPONENT INDEX NS/GS
Component Page
Seat Bel t I ndi cator Lamp . . . . . . . . . . . . . . . . .8W-40
Seat Bel t Swi tch. . . . . . . . . . . . . . . . . . . . . . . .8W-40
Sentry Key I mmobi l i zer Modul e. . . . . . . . . . . .8W-39
Servi ce Engi ne Soon Lamp . . . . . . . . . . . . .8W-30, 46
Sl i di ng Door Contacts. . . . . . . . . . . . . . . . . . . .8W-61
Sl i di ng Door Lock Motors . . . . . . . . . . . . . . . . .8W-61
Speed Control Swi tches . . . . . . . . . . . . . . .8W-30, 33
Speedometer . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-40
Stop Lamp Swi tch . . . . . . . . . . . . . . . . . . .8W-33, 51
Stop/Turn Si gnal Rel ays . . . . . . . . . . . . . . . . . .8W-54
Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-40
Tai l /Stop Lamp . . . . . . . . . . . . . . . . . . . . . . . . .8W-51
Tai l /Turn Si gnal Lamp . . . . . . . . . . . . . . . .8W-51, 52
Throttl e Posi ti on Sensor . . . . . . . . . . . . . . . . . .8W-30
Tracti on Control Swi tch . . . . . . . . . . . . . . . . . .8W-35
Trai l er Tow Connector . . . . . . . . . . . . . . . . . . .8W-54
Transmi ssi on Control Modul e. . . . . . . . . . . . . .8W-31
Transmi ssi on Control Rel ay . . . . . . . . . . . .8W-10, 31
Transmi ssi on Control Sol enoi ds . . . . . . . . . . . .8W-31
Transmi ssi on Range Sensor . . . . . . . . . . . . . . .8W-31
Tri p Odometer . . . . . . . . . . . . . . . . . . . . . . . . .8W-40
Component Page
Turbi ne Speed Sensor . . . . . . . . . . . . . . . . . . . .8W-31
Turbo Boost Pressure Sensor . . . . . . . . . . . . . .8W-30
Turn I ndi cators. . . . . . . . . . . . . . . . . . . . . .8W-46, 52
Turn Si gnal /Hazard Swi tch . . . . . . . . . . . .8W-46, 52
Underdri ve Sol enoi d. . . . . . . . . . . . . . . . . . . . .8W-31
Uni versal Garage Door Opener . . . . . . . . . . . .8W-49
Vacuum Sol enoi d . . . . . . . . . . . . . . . . . . . . . . .8W-33
Vehi cl e Speed Control Servo. . . . . . . . . . . . . . .8W-33
Vehi cl e Speed Sensor . . . . . . . . . . . . . . . . . . . .8W-30
Vent Motors . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-60
Vent Sol enoi ds . . . . . . . . . . . . . . . . . . . . . . . . .8W-33
Vi sor/Vani ty Mi rror Lamps. . . . . . . . . . . . . . . .8W-44
Vol tage Regul ator . . . . . . . . . . . . . . . . . . . . . . .8W-20
Vol ts I ndi cator Lamp . . . . . . . . . . . . . . . . . . . .8W-40
VTSS Lamp . . . . . . . . . . . . . . . . . . . . . . . .8W-39, 46
Washer Modul e. . . . . . . . . . . . . . . . . . . . . . . . .8W-53
Wheel Speed Sensors . . . . . . . . . . . . . . . . . . . .8W-35
Wi per Hi gh/Low Rel ay . . . . . . . . . . . . . . . . . . .8W-53
Wi per Modul e . . . . . . . . . . . . . . . . . . . . . . . . . .8W-53
Wi per On Rel ay . . . . . . . . . . . . . . . . . . . . . . . .8W-53
NS/GS 8W - 02 COMPONENT INDEX 8W - 02 - 3
8W-10 POWER DISTRIBUTION
Component Page
A/C Compressor Cl utch . . . . . . . . . . . . . . . . . . . . . . . .8W-10-29
A/C Compressor Cl utch Rel ay . . . . . . . . . . . . . . . .8W-10-10, 25, 29
Ai rbag Control Modul e . . . . . . . . . . . . . . . . . . . . . . . .8W-10-35
Automati c Shut Down Rel ay . . . . . . . . . . . . . . . . . . . .8W-10-9, 23
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-8, 27, 28
Body Control Modul e . . . . . . . . . . .8W-10-11, 14, 16, 17, 19, 21, 30, 32
BS15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-33
BS16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-34
BS19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-30
BS33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-25
Center Dome Lamp . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-21
Ci gar/Accessory Rel ay . . . . . . . . . . . . . . . . . . . . . .8W-10-10, 31
Cl ockspri ng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-30
Combi nati on Fl asher/DRL Modul e . . . . . . . . . . . . . . . .8W-10-29, 32
Control l er Anti -Lock Brake . . . . . . . . . . . . . . . . . . . .8W-10-15, 29
Courtesy Lamp Rel ay . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-21
Crank Case Heater . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-27
CS01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-21
CS02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-20
CS1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-21
Data Li nk Connector . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-11
Di esel Power Rel ay . . . . . . . . . . . . . . . . . . . . . . .8W-10-9, 25, 29
Door Lock Rel ay. . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-13
Door Unl ock Rel ay . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-13
Downstream Heated Oxygen Sensor . . . . . . . . . . . . . . . . .8W-10-23
Dri ver Door Courtesy Lamp . . . . . . . . . . . . . . . . . . . . .8W-10-21
Dri ver Door Unl ock Rel ay . . . . . . . . . . . . . . . . . . . . . .8W-10-13
Dri ver Power Mi rror . . . . . . . . . . . . . . . . . . . . . . .8W-10-12, 22
EGR Sol enoi d . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-25
Engi ne Starter Motor . . . . . . . . . . . . . . . . . . . . . . .8W-10-8, 16
Engi ne Starter Motor Rel ay . . . . . . . . . . . . . . . . . . . .8W-10-8, 16
ES01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-27, 28
ES06 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-25, 29
ES07 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-29
ES09 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-8
ES11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-8, 28
ES12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-23
ES26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-8
ES28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-8
ES29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-25, 29
ES40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-27
ES99 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-24
Fog Lamp Rel ay . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-33
Front Bl ower Motor . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-18
Front Bl ower Motor Rel ay . . . . . . . . . . . . . . . . . . . . .8W-10-8, 18
Front Ci gar Li ghter/Power Outl et . . . . . . . . . . . . . . . . . .8W-10-31
Front Readi ng Lamps/Swi tch . . . . . . . . . . . . . . . . . . . . .8W-10-20
Front Wi per Swi tch . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-19
FS01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-24
FS03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-23
Fuel Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-27
Fuel Heater Rel ay . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-9, 27
Fuel I njector No. 1 . . . . . . . . . . . . . . . . . . . . . . . .8W-10-23, 24
Fuel I njector No. 5 . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-24
Fuel I njector No. 6 . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-24
Fuel Pump Modul e . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-25
Fuel Pump Rel ay . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-9, 26
Fuel Tank Modul e. . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-26
Fuse 1 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-17
Fuse 1 (PDC) . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-14, 35
Fuse 2 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-11, 16
Fuse 2 (PDC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-35
Fuse 3 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-17
Fuse 4 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-17
Fuse 4 (PDC) . . . . . . . . . . . . . . . . . . . . . . .8W-10-10, 32, 33, 34
Fuse 5 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-17
Fuse 5 (PDC) . . . . . . . . . . . . . . . . . . . . . . .8W-10-10, 32, 33, 34
Fuse 6 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-16
Fuse 6 (PDC) . . . . . . . . . . . . . . . . . . . . . . .8W-10-10, 32, 33, 34
Fuse 7 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-12
Fuse 7 (PDC) . . . . . . . . . . . . . . . . . . . . . . .8W-10-10, 32, 33, 34
Fuse 8 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-16
Fuse 8 (PDC) . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-10, 31
Fuse 9 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-16
Fuse 9 (PDC) . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-10, 30
Fuse 10 (JB). . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-16
Fuse 10 (PDC). . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-10, 29
Fuse 11 (JB). . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-14
Fuse 11 (PDC). . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-10, 29
Fuse 12 (JB). . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-14, 18
Fuse 12 (PDC). . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-10, 29
Fuse 13 (PDC). . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-10, 29
Fuse 15 (PDC) . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-9, 28
Fuse 16 (JB). . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-27
Fuse 16 (PDC) . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-9, 26
Fuse 17 (PDC) . . . . . . . . . . . . . . . . . . . . . . .8W-10-9, 23, 25, 29
Fuse 18 (PDC) . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-9, 20
Component Page
Fuse 19 (PDC) . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-8, 19
Fuse 20 (PDC) . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-8, 19
Fuse 21 (PDC) . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-8, 18
Fuse 22 (PDC) . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-8, 17
Fuse 23 (PDC) . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-8, 16
Fuse 24 (PDC) . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-8, 15
Fuse 25 (PDC) . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-8, 15
Fuse 26 (PDC) . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-8, 13
Fuse 27 (PDC) . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-8, 12
Fuse 28 (PDC) . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-9, 11
Fusi bl e Li nk A11 . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-8
Fusi bl e Li nk A54 . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-8
G100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-27, 28
G103 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-27, 28
G200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-14, 32
G300 . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-14, 18, 19, 31
Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-8, 23, 25
Gl ove Box Lamp. . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-20
Gl ow Pl ug Rel ay . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-8, 25
Headl amp Di mmer Swi tch . . . . . . . . . . . . . . . . . . . . . .8W-10-32
Headl amp Swi tch . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-21, 34
Hi gh Beam Rel ay . . . . . . . . . . . . . . . . . . . . .8W-10-10, 32, 33, 34
Hi gh Note Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-30
Horn Rel ay . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-10, 30
Horn Swi tch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-30
HS6D S02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-13
I gni ti on Coi l Pack . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-23
I gni ti on Swi tch . . . . . . . . . . . . . . . . . . . . . . . .8W-10-11, 14, 16
I nstrument Cl uster . . . . . . . . . . . . . . . . . . . . . . . .8W-10-11, 14
Juncti on Bl ock . . . . . . . . . .8W-10-11, 12, 13, 14, 16, 17, 18, 20, 21, 22,
26, 27, 29, 30, 31, 32, 35
Key-I n Hal o Lamp . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-21
Left Headl amp . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-33, 34
Left Headl amp Level i ng Motor . . . . . . . . . . . . . . . . . . . .8W-10-34
Left Hi gh Headl amp . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-33
Left Li ftgate Fl ood Lamp . . . . . . . . . . . . . . . . . . . . . . .8W-10-21
Left Mi d Readi ng Lamp . . . . . . . . . . . . . . . . . . . . .8W-10-20, 21
Left Rear Readi ng Lamp . . . . . . . . . . . . . . . . . . . . .8W-10-20, 21
Left Vi sor/Vani ty Mi rror Lamps . . . . . . . . . . . . . . . . . . .8W-10-20
Low Beam Rel ay . . . . . . . . . . . . . . . . . . . . .8W-10-10, 32, 33, 34
Low Note Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-30
Memory Seat/Mi rror Modul e . . . . . . . . . . . . . . . . . . . . .8W-10-11
Message Center . . . . . . . . . . . . . . . . . . . . . .8W-10-11, 14, 33, 34
Name Brand Speaker Rel ay . . . . . . . . . . . . . . . . . . . . .8W-10-16
Park Lamp Rel ay . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-8, 17
Passenger Door Courtesy Lamp . . . . . . . . . . . . . . . . . . .8W-10-21
Passenger Power Mi rror . . . . . . . . . . . . . . . . . . . . .8W-10-12, 22
Power Di stri buti on Center .8W-10-8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19,
20, 23, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35
Power Mi rror Fol d Rel ay . . . . . . . . . . . . . . . . . . . . . . .8W-10-22
Power Mi rror Swi tch . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-20
Power Mi rror Unfol d Rel ay . . . . . . . . . . . . . . . . . . . .8W-10-21, 22
Power Seat Ci rcui t Breaker . . . . . . . . . . . . . . . . . . . . .8W-10-13
Powertrai n Control Modul e. . . . . . . . . . . .8W-10-16, 23, 25, 26, 27, 29
PTC 1 (JB) . . . . . . . . . . . . . . . . . . . . . .8W-10-16, 26, 27, 29, 35
PTC 3 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-13
PTC 7 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-16, 31
PTC 8 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-16
PTC 9 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-16
Radi ator Fan Rel ay . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-15
Radi ator Fan Rel ay No. 1. . . . . . . . . . . . . . . . . . . . . . .8W-10-25
Radi ator Fan Rel ay No. 2. . . . . . . . . . . . . . . . . . . . .8W-10-15, 25
Radi ator Fan Rel ay No. 3. . . . . . . . . . . . . . . . . . . . .8W-10-19, 25
Radi o. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-11
Rear Ci gar Li ghter/Power Outl et. . . . . . . . . . . . . . . . . . .8W-10-31
Rear Dome Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-21
Rear Wi ndow Defogger . . . . . . . . . . . . . . . . . . . . . . . .8W-10-12
Rear Wi ndow Defogger Rel ay . . . . . . . . . . . . . . . . . . . . .8W-10-12
Remote Keyl ess Entry Modul e . . . . . . . . . . . . . . . . . . . .8W-10-11
Ri ght Headl amp. . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-33, 34
Ri ght Headl amp Level i ng Motor . . . . . . . . . . . . . . . . . . .8W-10-34
Ri ght Hi gh Headl amp. . . . . . . . . . . . . . . . . . . . . . . . .8W-10-33
Ri ght Li ftgate Fl ood Lamp . . . . . . . . . . . . . . . . . . . . . .8W-10-21
Ri ght Low Headl amp . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-33
Ri ght Mi d Readi ng Lamp . . . . . . . . . . . . . . . . . . . . .8W-10-20, 21
Ri ght Rear Readi ng Lamp . . . . . . . . . . . . . . . . . . . .8W-10-20, 21
Ri ght Vi sor/Vani ty Mi rror Lamps . . . . . . . . . . . . . . . . . .8W-10-20
Sentry Key I mmobi l i zer Modul e . . . . . . . . . . . . . . . . . . .8W-10-20
Stop Lamp Swi tch. . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-29
Transmi ssi on Control Modul e . . . . . . . . . . . . . . . . . .8W-10-16, 28
Transmi ssi on Control Rel ay . . . . . . . . . . . . . . . . . . . .8W-10-9, 28
Transmi ssi on Control Sol enoi ds . . . . . . . . . . . . . . . . . . .8W-10-28
Uni versal Garage Door Opener . . . . . . . . . . . . . . . . . . . .8W-10-20
Upstream Heated Oxygen Sensor . . . . . . . . . . . . . . . . . .8W-10-23
Vehi cl e Speed Sensor . . . . . . . . . . . . . . . . . . . . . . .8W-10-27, 29
Washer Modul e . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-13
Wi per Hi gh/Low Rel ay . . . . . . . . . . . . . . . . . . . . . . . .8W-10-19
Wi per Modul e . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-19
Wi per On Rel ay . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-8, 19
NS/GS 8W - 10 POWER DISTRIBUTION 8W - 10 - 1
86
85
30 87
87
85
30
86
POWER
DISTRIBUTION
CENTER
27
1
86
30
85
87
87
85
30
86
87
85
30
86
87
85
30
86
86
30
85
87
87
85
30
86
86
87 30
85
85
30 87
86
86
30
85
87
86
30
85
87
87
85
30
86
86
30
85
87
86
30
85
87
2
4
3
87A
7
8
6
5
10
9
12
11
14
13
16
15
18
17
19
20
21
22
23
24
25
26
SPARE
SPARE
HORN
RELAY
RELAY
CLUTCH
COMPRESSOR
A/C
FRONT
BLOWER
MOTOR
RELAY
ENGINE
STARTER
MOTOR
RELAY
PARK
LAMP
RELAY
CIGAR/
ACC.
RELAY
LOW
HIGH/
WIPER
RELAY
RELAY
ON
WIPER
HIGH
BEAM
RELAY
RELAY
BEAM
LOW
RELAY
CONTROL
TRANSMISSION
FUEL
PUMP
RELAY
AUTOMATIC
SHUT
DOWN
RELAY
IOD
(GAS)
(GAS)
(DIESEL)
RELAY
HEATER
FUEL
(GAS)
RELAY
POWER
DIESEL
87A 87A
87A
87A 87A
87A 87A
87A 87A
87A
87A
87A
87A
87A
28
8W - 10 - 2 8W-10 POWER DISTRIBUTION NS/GS
J988W-1 GS001002
FUSES
FUSE NO. AMPS FUSED CIRCUIT FEED CIRCUIT
1
10A
F23 18DB/YL
F87 18WT/BK
F14 18LG/YL
10A
2
3
- SPARE
L33 20RD 10A
4
L34 20RD/OR
10A
5
6
20A
L44 20VT/RD
8
20A INTERNAL
INTERNAL 20A
9
11
15A
A20 12RD/DB
10
20A
INTERNAL
F32 18PK/DB
25A
12
SPARE
20A
13
A5 18RD/DB
-
14
15*
20A
A14 18RD/WT*
16
INTERNAL
F41 20PK/VT
A17 12RD/BK
20A
17
18
15A
30A
19
40A
21
40A
22
40A
23
40A
24
40A
25
40A
26
40A
27
40A
28
10A
20A
A22 12BK/OR
A0 6RD
INTERNAL
A0 6RD
A0 6RD
A0 6RD
A0 6RD
A0 6RD
A0 6RD
A0 6RD
A0 6RD
A0 6RD
A0 6RD
A0 6RD
A0 6RD
A0 6RD
A0 6RD
A0 6RD
A0 6RD
L9 18BK/WT
A1 12RD
A16 12GY
A10 12RD/DG
A2 12PK/BK
A4 12BK/RD
M1 20PK
L43 18VT
7
15A
A0 6RD
A0 6RD
A0 6RD
A0 6RD
A0 6RD
INTERNAL
L34 20RD/OR
20**
INTERNAL
INTERNAL
INTERNAL
INTERNAL
INTERNAL
INTERNAL
* GAS
** DIESEL
F23 20DB/YL
F14 20LG/YL
BUILT-UP-EXPORT
EXCEPT BUILT-UP-EXPORT
NS/GS 8W-10 POWER DISTRIBUTION 8W - 10 - 3
GS001003 J988W-1
- -
CIGAR/ACCESSORY RELAY OUTPUT F30 16RD
FUSED IGNITION (RUN-ACC) F1 20DB
GROUND Z1 18BK
INTERNAL FUSED B (+)
87
87A
86
85
30
CIGAR/ACCESSORY RELAY
FUNCTION CAVITY CIRCUIT
CIRCUIT CAVITY FUNCTION
AUTOMATIC SHUT DOWN RELAY (GAS)
30
85
86
87A
FUSED B (+) INTERNAL
K51 18DB/YL AUTOMATIC SHUTDOWN RELAY CONTROL
A0 6RD B (+)
A142 18DG/OR ASD RELAY OUTPUT
- -
-
A/C COMPRESSOR CLUTCH RELAY OUTPUT C3 18DB/BK
FUSED IGNITION (ST-RUN) F87 18WT/BK*
A/C COMPRESSOR CLUTCH RELAY CONTROL C13 18DB/OR*
87A
86
85
30
A/C COMPRESSOR CLUTCH RELAY
87
85
86
C13 20DB/OR**
A142 18DG/OR**
87
DIESEL POWER RELAY
30
85
86
87A
87
K51 20DB/YL DIESEL POWER RELAY CONTROL
A0 6RD B (+)
A142 18DG/OR DIESEL POWER RELAY OUTPUT
- -
*GAS
**DIESEL
-
A/C COMPRESSOR CLUTCH RELAY CONTROL
FUSED IGNITION (ST-RUN)
J988W-1 GS001004
- -
FUEL PUMP RELAY OUTPUT A141 16DG/WT
FUSED IGNITION (ST-RUN) F87 18 WT/BK
FUEL PUMP RELAY CONTROL K31 18BR
87A
86
85
30
FUEL PUMP RELAY (GAS)
FRONT BLOWER MOTOR RELAY
30
85
86
87A
Z1 18BK GROUND
F20 20WT FUSED IGNITION (RUN)
C71 12DB FRONT BLOWER MOTOR RELAY OUTPUT
- -
- -
ENGINE STARTER MOTOR RELAY OUTPUT T40 12BR
FUSED IGNITION (ST) F45 18YL/RD
ENGINE STARTER MOTOR RELAY CONTROL K90 18TN
87A
86
85
30
ENGINE STARTER MOTOR RELAY
86
T141 20YL/RD
87
EATX
MTX
- -
FUEL HEATER RELAY OUTPUT A141 16DG/WT
FUSED IGNITION (ST-RUN) INTERNAL
GROUND Z1 20BK
87A
86
85
30
FUEL HEATER RELAY (DIESEL)
87
87
87
FUSED IGNITION (ST)
GS001005 J988W-1
FUSED B (+)
PARK LAMP RELAY
30
85
86
87A
FUSED B (+)
L97 18PK/DB PARK LAMP RELAY CONTROL
L7 12BK/YL PARK LAMP RELAY OUTPUT
- -
- -
LOW BEAM RELAY OUTPUT INTERNAL
B (+) A0 6RD
LOW BEAM RELAY CONTROL L94 20OR/WT
A0 6RD B (+)
87
86
85
30
LOW BEAM RELAY
85
L193 20OR/WT * LOW BEAM RELAY CONTROL
* CHRYSLER
- -
HIGH BEAM RELAY OUTPUT INTERNAL
B (+) A0 6RD
HIGH BEAM RELAY CONTROL L324 20WT/LG
A0 6RD B (+)
87A
86
85
30
HIGH BEAM RELAY
HORN RELAY
30
85
86
87A
X4 20GY/OR HORN RELAY CONTROL
A0 6RD B (+)
X2 18DG/RD HORN RELAY OUTPUT
- -
87
87
87A
INTERNAL
INTERNAL
87
J988W-1 GS001006
FUSED B(+)
WIPER ON RELAY
30
85
86
87
WIPER ON RELAY OUTPUT
V14 18RD/VT WIPER ON RELAY CONTROL
FUSED B(+)
87A
Z1 18BK GROUND
WIPER HIGH/LOW RELAY OUTPUT (LOW) V3 12BR/WT
87A
WIPER HIGH/LOW RELAY OUTPUT (HIGH) V4 12RD/YL
V16 20WT WIPER HIGH/LOW RELAY CONTROL
87
86
85
30
WIPER HIGH/LOW RELAY
TRANSMISSION CONTROL RELAY (GAS)
30
85
86
87A
Z16 18BK GROUND
T15 18LG 12 V SUPPLY
T16 18RD TRANSMISSION CONTROL RELAY OUTPUT
- -
87
INTERNAL
INTERNAL
INTERNAL
INTERNAL
INTERNAL
GS001007 J988W-1
CENTER
DISTRIBUTION
POWER
BATTERY
ENGINE
STARTER
MOTOR
A0
6
RD
RD
6
A0
TO
JUNCTION
BLOCK
PK/BK
12
A2
C4
5
26
FUSE
40A 40A
FUSE
25
6
C4
A10
12
RD/DG
ANTI-LOCK
CONTROLLER
TO
BRAKE
RELAY
TO
RADIATOR
FAN
GY
12
A16
C7
6
24
FUSE
40A
TO
IGNITION
SWITCH
RD
12
A1
C4
3
23
FUSE
40A
30
ENGINE
STARTER
MOTOR
RELAY
RELAY
LAMP
PARK
30
40A
FUSE
22
86
21
FUSE
40A
30
FRONT
BLOWER
RELAY
40A
FUSE
20
87
19
FUSE
30A
86
WIPER
ON
RELAY
40A
FUSE
27
6
C1
A4
12
BK/RD
BLOCK
JUNCTION
TO
GENERATOR
A11
6
BK/GY
ES09
A11
LINK
FUSIBLE
10
DG
A
(8W-10-9)
MOTOR
TO
FUSE
28 (PDC)
4
C7
A17
12
RD/BK
FAN RELAY
RADIATOR
TO
NO. 3
FAN RELAY
RADIATOR
TO
NO. 2
DIESEL GAS
RD
2
A0
DIESEL GAS
ES11
DIESEL GAS
RELAY
PLUG
GLOW
(DIESEL)
1
RD
10
FUSIBLE
LINK
A54
ES26
ES28
A54
10
RD
(DIESEL)
(8W-20-2)
(8W-20-3)
(8W-21-2)
(8W-21-3)
(8W-10-13) (8W-10-15) (8W-10-15) (8W-10-16)
(8W-21-2)
(8W-21-3)
(8W-10-17)
(8W-50-11)
(8W-50-12) (8W-42-2)
(8W-53-2)
(8W-53-3)
(8W-10-19)
(8W-10-12)
(8W-20-2)
(8W-20-3)
(8W-10-18)
(8W-10-19)
(8W-30-32)
J988W-1 GS001008
CENTER
DISTRIBUTION
POWER
BLOCK
JUNCTION
TO
30
20A
FUSE
15
10
C8
A5
18
RD/DB
MODULE
TO
TRANSMISSION
CONTROL
RELAY
CONTROL
TRANSMISSION
AUTOMATIC
SHUT
DOWN
RELAY
17
FUSE
20A
30
TO
JUNCTION
BLOCK
PK/VT
20
F41
C2
2
18
FUSE
15A 10A
FUSE
28
5
C3
M1
20
PK PK
20
M1
TO
MEMORY
SEAT/
MIRROR
MODULE
TO
FUSE
13 (PDC)
FROM
FUSE
19 (PDC)
(GAS)
30
20A
FUSE
16
9
C6
RELAY
HEATER
FUEL
A14
18
RD/WT
MODULE
TO
POWERTRAIN
CONTROL
(DIESEL)
30
20A
FUSE
16
RELAY
PUMP
FUEL
(GAS)
30
25A
FUSE
17
RELAY
POWER
DIESEL
(DIESEL) (GAS)
86 86
A
(8W-10-8)
B
(8W-10-10)
(8W-10-28)
(8W-31-2)
(8W-30-2)
(8W-10-20) (8W-10-11)
(8W-30-29)
(8W-10-26)
(8W-30-6)
(8W-30-20)
(8W-10-26)
(8W-10-25)
(8W-30-28)
(8W-10-23)
GS001009 J988W-1
TO
RIGHT
HEADLAMP
15 (PDC)
FUSE
FROM
BLOCK
JUNCTION
20A
FUSE
10
9
C5
L9
18
BK/WT
TO
86 30
HORN
RELAY
9
FUSE
20A
CIGAR/
ACCESSORY
RELAY
8
FUSE
20A
30
15A
FUSE
7
BEAM
LOW
30 86
87
6
FUSE
20A
C3
1 8
C5
RELAY
L43
18
VT
TO
BS16
RD
20
L33
RD/OR
20
L34
RELAY
C5
1 6
C5
10A
FUSE
4
87
86 30
HIGH
BEAM
5
FUSE
10A
CENTER
DISTRIBUTION
POWER
B
(8W-10-9)
TO
PK/DB
18
F32
C3
8
13
FUSE
20A
SWITCH
STOP
LAMP ANTI-LOCK
CONTROLLER
BRAKE
25A
FUSE
12
6
C3
A20
12
RD/DB
TO
30
15A
FUSE
11
CLUTCH
COMPRESSOR
A/C
RELAY
EXCEPT
BUILT-UP
-EXPORT
BUILT-UP
-EXPORT -EXPORT
BUILT-UP
EXCEPT
BUILT-UP
-EXPORT
CHRYSLER PLYMOUTH
DODGE/
PLYMOUTH
DODGE/
CHRYSLER
OTHER CHRYSLER OTHER CHRYSLER
VT/RD
20
L44
VT/RD
20
L44
VT/RD
20
L44
VT
18
L43
VT
18
L43
L34
20
RD/OR
L34
20
RD/OR
L33
20
RD
HEADLAMP
RIGHT
TO TO
HEADLAMP
LOW
RIGHT
BS15
TO
FOG
LAMP
RELAY
(IN JB)
TO
TO
LEFT
HEADLAMP
RIGHT
HIGH
HEADLAMP
TO
TO
LEFT
HIGH
TO
HEADLAMP
LEFT
MESSAGE
TO
CENTER
HEADLAMP
(8W-10-29)
(8W-41-2)
(8W-10-30)
(8W-41-3)
(8W-10-31)
(8W-10-33)
(8W-10-34)
(8W-50-2)
(8W-10-33)
(8W-10-34)
(8W-10-33)
(8W-10-34)
(8W-50-2)
(8W-10-33)
(8W-10-34)
(8W-10-29) (8W-10-29) (8W-10-29)
(8W-10-29)
J988W-1 GS001010
BATT A0
10A
FUSE
28
CENTER
DISTRIBUTION
POWER
5
C3
M1
20
PK
JUNCTION
BLOCK
13 C1
16
MODULE
MIRROR
SEAT/
MEMORY
C1
M1
20
PK
C4
6 13
C4
17
C4
9
MODULE
BODY
CONTROL
REMOTE
KEYLESS
ENTRY
MODULE
3
M1
20
PK
12
CENTER
MESSAGE
PK
20
M1
C3
2
C3 1
3
0
2
1 4
SWITCH
IGNITION
M1
20
PK
A81
20
DG/RD
INSTRUMENT
CLUSTER
2
M1
20
PK
C1
RADIO
7
M1
20
PK
M1
20
PK
16
DATA LINK
CONNECTOR
BLOCK
JUNCTION
10A
FUSE
2
C4 15
D1
D3
*8
7 P50
NOT
USED
* RHD
M1
22
PK
4 ACC
3 LOCK
0 OFF
2 RUN
1 START
(8W-10-8)
(8W-10-9)
(8W-12-2)
(8W-62-3)
(8W-63-4)
(8W-45-2)
(8W-61-5)
(8W-46-2)
(8W-10-14)
(8W-40-2)
(8W-47-2)
(8W-30-3)
(8W-12-2)
(8W-12-9)
GS001011 J988W-1
(8W-30-30)
BATT A0
40A
FUSE
27
A4
12
BK/RD
CENTER
DISTRIBUTION
POWER
JUNCTION
BLOCK
30
87
6
C1
35 C1
REAR
WINDOW
DEFOGGER
RELAY
10A
FUSE
7
C4
20
4
DRIVER
POWER
MIRROR
MIRROR
POWER
PASSENGER
4
DEFOGGER
WINDOW
REAR
C15
12
BK/WT
12
B17
LJ01
C15
12
BK/WT
L16
J03A
1
C15
12
BK/WT
6
C1
C1
C1
C16
20
LB/YL
C16
20
LB/YL
(8W-10-8)
(8W-10-8)
(8W-12-2)
(8W-48-2)
(8W-12-10)
(8W-48-2)
(8W-48-2)
(8W-48-2)
J988W-1 GS001012
JUNCTION
BLOCK
30
87 86
RELAY
UNLOCK
DOOR DOOR
LOCK
RELAY
86 87
30 30
87 86
UNLOCK
DOOR
DRIVER
RELAY
(RKE)
4
C4 C1
33
1
A2
12
PK/BK
A2
12
PK/BK
A3
12
PK/BK
C
(8W-10-14)
IGNITION
SWITCH
TO
S02
B09
2
2
HS6D
S02
HS5D
B09
3
A2
12
PK/BK
OTHER
HEATED
SEATS
BATT A0
9A
3
PTC
40A
FUSE
26
CENTER
DISTRIBUTION
POWER
5
C4
4 C1
A2
12
PK/BK
85 85 85
87A 87A 87A
30A
BREAKER
CIRCUIT
SEAT
POWER
P
WASHER
MODULE
(BUILT-UP
-EXPORT
(8W-12-2)
(8W-61-3)
(8W-61-4)
(8W-61-7)
(8W-61-8)
(8W-61-3)
(8W-61-4)
(8W-61-7)
(8W-61-8)
(8W-61-7)
(8W-61-8)
(8W-10-8)
(8W-12-14)
(8W-12-15)
(8W-10-8)
(8W-63-2)
(8W-63-3)
(8W-63-4)
(8W-53-5)
GS001013 J988W-1
BK
20
Z1
CLUSTER
INSTRUMENT
13
BODY
CONTROL
MODULE
4
C2
BK
14
Z1
JUNCTION
BLOCK
28 C4
2
C2
G300
8
2
C2
Z1
20
BK
1 C2
G26
20
LB
SWITCH
KEY-IN
14
G200
BK
20
Z1
C1
1
3
0
2
1 4
BK/OR
12
A22
4
C1
3 C1
PK/BK
12
A2
4 1
2
0
3
BATT A1
A1
12
RD
ST-RUN A21
DB
12
A21
RUN-ACC A31
A31
12
BK/WT
ST A41
A41
12
YL
ST-RUN-OFF A81
A81
20
DG/RD
PK
20
M1
BATT M1
C1
10
C1 7
3
0
2
1 4
SWITCH
IGNITION
C1
9
3
0
2
1 4
8
C1 C3
2
C3 1
3
0
2
1 4
2 C1
G9
20
GY/BK
9
MESSAGE
CENTER BLOCK
JUNCTION
8
C3
G9
20
GY/BK
C
(8W-10-13)
FROM
BLOCK
JUNCTION
CENTER
DISTRIBUTION
POWER
10A
FUSE
1
2 C3
11
FUSE
20A
BLOCK
JUNCTION
C4 1
12
FUSE
10A
31
C2
A22
12
BK/OR
1 START
2 RUN
0 OFF
3 LOCK
4 ACC
*11
* RHD
(8W-40-4)
(8W-45-5)
(8W-12-19)
(8W-15-6)
(8W-15-4)
(8W-10-16)
(8W-10-16)
(8W-10-16)
(8W-46-3) (8W-12-2)
(8W-10-16)
(8W-10-11)
(8W-10-35)
(8W-12-11)
(8W-12-2)
(8W-10-35)
(8W-12-12)
(8W-10-16)
J988W-1 GS001014
BATT A0
40A
FUSE
25
A10
12
RD/DG
CENTER
DISTRIBUTION
POWER
6
C4
25
CONTROLLER
ANTI-LOCK
BRAKE
24
FUSE
40A
C7
6
GY
12
A16
RELAY
FAN
RADIATOR
4
GAS DIESEL
8
A16
12
GY
NO. 2
RELAY
FAN
RADIATOR
A16
12
GY
(8W-10-8)
(8W-10-8)
(8W-35-2) (8W-42-8)
(8W-42-10)
GS001015 J988W-1
BATT A0
CENTER
DISTRIBUTION
POWER
ENGINE
STARTER
MOTOR
RELAY
A1
12
RD
3
C4
40A
FUSE
23
C7
3
BR
12
T40
MOTOR
STARTER
ENGINE
P18
B23
4
B4
87 85
86 30
4
C6
C1
POWERTRAIN
CONTROL
MODULE
3 C2
C8
7
8
DG/RD
20
A81
BATT M1
M1
20
PK
4 1
2
0
3
1 C3
2
C3
15 C4 C4 31
2
FUSE
10A
9A
1
PTC
20A
FUSE
6
31 C3
RELAY
SPEAKER
BRAND
NAME
30
9A
9
PTC
PTC
8
9A
9A
7
PTC
FUSE
10
10A
C1
8
BK/WT
12
A31 A21
12
DB YL
12
A41
4 1
2
0
3
9
C1
IGNITION
SWITCH
4 1
2
0
3
7 C1
10
C1
8
FUSE
10A
C4 7
BLOCK
JUNCTION
F45
18
YL/RD
A1
12
RD
TRANSMISSION
CONTROL
MODULE
D1
D3
BODY
CONTROL
MODULE
14
1 START
2 RUN
0 OFF
3 LOCK
4 ACC
31
15A
FUSE
9
ST F45 ST T141
MTX EATX
F45
20
YL/RD
T141
20
YL/RD
3
MODULE
CONTROL
POWERTRAIN
6
E95
B107
DIESEL GAS
K90
18
TN
K90
18
TN
K90
20
TN
(8W-10-8)
(8W-10-8)
(8W-21-2)
(8W-21-3)
(8W-30-6)
(8W-30-20)
(8W-12-20)
(8W-12-9)
(8W-12-13)
(8W-12-9)
(8W-47-4)
(8W-12-16)
(8W-12-16)
(8W-12-16)
(8W-12-16)
(8W-10-14)
(8W-12-11)
(8W-12-2)
(8W-31-5)
(8W-45-2)
(8W-12-11)
(8W-12-16) (8W-12-16)
(8W-30-28)
J988W-3 GS001016
BATT A0
40A
FUSE
22
CENTER
DISTRIBUTION
POWER
10
C3
85 87
30 86
RELAY
LAMP
PARK
C1
4
BLOCK
JUNCTION
C2 9 2 C1
16
3
FUSE
15A
L7
12
BK/YL
BODY
CONTROL
MODULE
L97
18
PK/DB
15A
FUSE
5
1
10A
FUSE
1
FUSE
4
(BUILT-UP
15A
-EXPORT)
(8W-10-8)
(8W-10-8)
(8W-12-2)
(8W-12-8)
(8W-45-3)
(8W-12-8)
(8W-12-8) (8W-12-8)
GS001017 J988W-3
BATT A0
CENTER
DISTRIBUTION
POWER
21
FUSE
40A
FRONT
BLOWER
MOTOR
2
C4
DB
12
C71
1
FRONT
BLOWER
MOTOR
B35
P18
B23
35
C71
12
DB
85 87
30 86
C1
3
G300
10
Z1
18
BK
5 C2
JUNCTION
BLOCK
10A
FUSE
12
7
C2
RUN A22
F20
20
WT
RELAY
(8W-10-8)
(8W-10-8)
(8W-42-2)
(8W-15-7)
(8W-12-2)
(8W-12-12)
(8W-10-14)
J988W-3 GS001018
BATT A0
40A
FUSE
20
CENTER
DISTRIBUTION
POWER
19
FUSE
30A
86
30
87
86 30
87 87A
C5
4 3
C5
V4
12
RD/YL BR/WT
12
V3
3 1
WIPER
MODULE
85
85
87A
7
C5 C5
5
C4
2
V14
18
RD/VT
C1 73
MODULE
CONTROL
BODY
5
V16
20
WT
G300
10
Z1
18
BK
B1
P18
B23
1
V16
20
WT
SWITCH)
FUNCTION
MULTI-
(PART OF
SWITCH
WIPER
FRONT
WIPER
ON
RELAY
WIPER
HIGH/
LOW
RELAY
(DIESEL)
C7
4
8
RD/BK
12
A17
NO. 3
RELAY
FAN
RADIATOR
(8W-10-8)
(8W-10-8)
(8W-53-2)
(8W-45-4)
(8W-15-7)
(8W-53-2)
(8W-53-3)
(8W-53-2)
(8W-53-3)
(8W-53-2)
(8W-42-10)
GS001019 J988W-3
BATT A0
15A
FUSE
18
CENTER
DISTRIBUTION
POWER
2
C2
F41
20
PK/VT
JUNCTION
BLOCK
15 C2
C2
19 16
C3
20
C3
POWER
MIRROR
9
F41
20
PK/VT
SWITCH LAMP
PK/VT
20
F41
1
BOX
GLOVE
PK/VT
20
F41
LEFT
3
MID
LAMP
READING
READING
LAMP
MID
RIGHT
READING
LAMP
REAR
LEFT
RIGHT
REAR
LAMP
READING
D
(8W-10-21)
TO
COURTESY
LAMP
RELAY
3
3
3
B
VANITY
MIRROR
VISOR/
LEFT
LAMPS
LAMPS
RIGHT
VISOR/
MIRROR
VANITY
B
3
LAMPS/
SWITCH
READING
FRONT
F41
20
PK/VT
F41
20
PK/VT
PK/VT
20
F41
PK/VT
20
F41 F41
20
PK/VT PK/VT
20
F41
PK/VT
20
F41
CS02
OVERHEAD
CONSOLE OTHERS
C20
B75
2
PK/VT
20
F41
FRONT
READING
SWITCH
LAMPS/
4
4
OPENER
DOOR
GARAGE
UNIVERSAL
F41
20
PK/VT
1
MODULE
IMMOBILIZER
KEY
SENTRY
F41
20
PK/VT
LAMPS/
READING
FRONT
(PART OF
SWITCH)
(BUILT-UP
-EXPORT)
(8W-10-8)
(8W-10-9)
(8W-12-2)
(8W-62-2)
(8W-62-4)
(8W-44-2)
(8W-44-4)
(8W-44-4)
(8W-44-4)
(8W-44-4)
(8W-44-3)
(8W-44-3)
(8W-44-2)
(8W-44-2)
(8W-49-3)
(8W-39-5)
J988W-3 GS001020
PK/LB
20
M11
M11
20
PK/LB
D01P
B03
6
3
B01
D02
PK/LB
20
M11
PK/LB
20
M11
1
COURTESY
LAMP
DOOR
DRIVER
PASSENGER
DOOR
LAMP
COURTESY
1
1
FLOOD
LAMP
LIFTGATE
RIGHT
PK/LB
20
M11
LEFT
LIFTGATE
LAMP
FLOOD
1
M11
20
PK/LB
3
J02A
L15
PK/LB
20
M11
LJ01
B17
3
M11
20
PK/LB
M11
20
PK/LB
KEY-IN
HALO
2
LAMP
C2
6 29
C2 C3
29
CS01
1
RIGHT
REAR
LAMP
READING
READING
LAMP
REAR
1
LEFT
M113
20
LB/PK
M113
20
LB/PK LB/PK
20
M113
LB/PK
20
M113
LEFT
1
MID
LAMP
READING
READING
LAMP
MID
RIGHT
1
C2
22
LB/PK
20
M113 M112
22
BR/LG
10
C3
3 C1
17
M113
20
LB/PK
28
C3
C1 C1 11
C3
34
85
BLOCK
JUNCTION
FROM
D
(8W-10-20)
JUNCTION
BLOCK
COURTESY
LAMP
RELAY
87
30 86
SWITCH
BR/WT
22
M111
9
HEADLAMP
CONTROL
BODY
MODULE
D4
C20
B75
4
2
CENTER
DOME
LAMP
LAMP
DOME
REAR
2
CS1
M113
20
LB/PK
M113
20
LB/PK
F
(8W-10-22)
POWER
TO
MIRROR
UNFOLD
RELAY
(BUILT-UP-EXPORT)
(8W-44-3)
(8W-44-3)
(8W-44-4) (8W-44-4)
(8W-44-3)
(8W-44-4)
(8W-44-4) (8W-44-4)
(8W-44-4)
(8W-12-2)
(8W-50-9)
(8W-50-10)
(8W-45-4)
(8W-44-4)
(8W-44-4)
GS001021 J988W-3
RELAY
LAMP
COURTESY
FROM
DG
20
P159
DG
20
P159
LB
20
P160
LB
20
P160
M
MIRROR
5
POWER
PASSENGER
6
6
DRIVER
POWER
5
MIRROR
11
C3 C4
11
F
(8W-10-21)
86 87
30 85
FOLD
MIRROR
POWER
RELAY RELAY
85
POWER
MIRROR
UNFOLD
30
87 86
JUNCTION
BLOCK
C2 C2
C2 C2
87A 87A
M
(8W-62-8)
(8W-62-8)
(8W-62-8) (8W-62-8)
(8W-12-2)
8W - 10 - 22 8W-10 POWER DISTRIBUTION
BUILT-UP-EXPORT
NS/GS
J988W-3 GS001022
BATT A0
20A
FUSE
17
CENTER
DISTRIBUTION
POWER
DOWN
SHUT
AUTOMATIC
C6
5
DG/OR
18
A142
MODULE
CONTROL
POWERTRAIN
85 87
30 86
8
C6
C2 67
DB/YL
18
K51
RELAY
ES12
FS03
A142
18
DG/OR
DOWNSTREAM
HEATED
OXYGEN
SENSOR
SENSOR
OXYGEN
HEATED
UPSTREAM
DG/OR
A142
GENERATOR
1
A142
18
DG/OR
6 C1
POWERTRAIN
CONTROL
MODULE
A142
DG/OR
PACK
COIL
IGNITION
**2
DG/OR
A142
E
(8W-10-24)
TO
E78
A142
DG/OR
A142
18
DG/OR
NO. 1
INJECTOR
FUEL
2
2.4L 3.3L/3.8L
18 18 18 18
2
FUEL
INJECTOR
NO. 2
DG/OR
18
A142
2
FUEL
INJECTOR
NO. 3
DG/OR
18
A142
2
FUEL
INJECTOR
NO. 4
DG/OR
18
A142
A142
18
DG/OR
B70
E43
2
F09
E69
10
2
DG/OR
18
A142
2
*3
DG/OR
18
A142
2.0L
ES99
TO
G
(8W-10-24)
(2.4L)
* 3.3L/3.8L
** 2.0L/2.4L
(8W-10-8)
(8W-10-9)
(8W-30-2)
(8W-30-7)
(8W-30-21)
(8W-30-7)
(8W-30-21)
(8W-20-2)
(8W-30-2)
(8W-30-8)
(8W-30-14)
(8W-30-22)
(8W-30-15) (8W-30-15) (8W-30-15) (8W-30-15)
NS/GS 8W-10 POWER DISTRIBUTION
GAS
8W - 10 - 23
GS001023 J988W-3
DG/OR
18
A142
FS01
A142
18
DG/OR
NO. 4
INJECTOR
FUEL
1
A142
18
DG/OR
NO. 3
INJECTOR
FUEL
1
A142
18
DG/OR
NO. 2
INJECTOR
FUEL
1
1
FUEL
INJECTOR
NO. 1
DG/OR
18
A142
1
FUEL
INJECTOR
NO. 5
DG/OR
18
A142
1
FUEL
INJECTOR
NO. 6
DG/OR
18
A142
DG/OR
18
A142
E
(8W-10-23)
ES12
FROM
F02
E78
1
(2.0L)
A142
18
DG/OR
NO. 4
INJECTOR
FUEL
2
A142
18
DG/OR
NO. 3
INJECTOR
FUEL
2
A142
18
DG/OR
NO. 2
INJECTOR
FUEL
2 2
FUEL
INJECTOR
NO. 1
DG/OR
18
A142
ES99
FROM
ES12
G
(8W-10-23)
A142
18
DG/OR
(3.3L/3.8L)
(8W-30-23)
(8W-30-23)
(8W-30-23)
(8W-30-23) (8W-30-23)
(8W-30-23)
(8W-30-9) (8W-30-9) (8W-30-9) (8W-30-9)
GAS
NS/GS
J988W-3 GS001024
DG/OR
18
A142
DG/OR
18
A142
10 9
B108
E96
3
A142
18
DG/OR
A142
18
DG/OR
A142
18
DG/OR
A142
18
DG/OR
18
A142
DG/OR
RELAY
FAN
RADIATOR
4
NO. 3
RELAY
FAN
RADIATOR
4
NO. 2
NO. 1
4
RADIATOR
FAN
RELAY
RELAY
PLUG
GLOW
3
DG/OR
18
A142
1
A142
16
DG/OR
68
DG/OR
16
A142
DG/OR
16
A142
23 45
POWERTRAIN
CONTROL
MODULE
DG/OR
18
A142
DG/OR
18
A142
1
B108
E96
7
BS33
ES29
BATT A0
20A
FUSE
17
CENTER
DISTRIBUTION
POWER
C6
5
DG/OR
18
A142
MODULE
CONTROL
POWERTRAIN
85 87
30 86
8
C6
42
DB/YL
20
K51
ES06
GENERATOR
A142
18
DG/OR
DIESEL
POWER
RELAY
SOLENOID
EGR
FUEL
PUMP
MODULE
86
A/C
COMPRESSOR
CLUTCH
RELAY
POWER
DISTRIBUTION
CENTER
1 C6
85
(8W-42-10)
(8W-42-10)
(8W-42-10)
(8W-30-32)
(8W-30-28)
(8W-10-8)
(8W-10-9)
(8W-30-28)
(8W-20-3)
(8W-30-29)
(8W-30-33)
(8W-42-9)
(8W-10-10)
DIESEL
8W - 10 - 25
GS001025 J988W-3
BATT A0
20A
FUSE
16
CENTER
DISTRIBUTION
POWER
9
C6
A14
18
RD/WT
FUEL
TANK
4
MODULE
RELAY
PUMP
FUEL
C2
7
DG/WT
16
A141
MODULE
46
CONTROL
POWERTRAIN
C2
85 87
30 86
3
C6
BLOCK
JUNCTION
30
C1
9A
1
PTC
ST-RUN A21
6 C2
F87
18
WT/BK
C2 74
BR
18
K31
4
B13
AW4
(8W-10-8)
(8W-10-9)
(8W-30-6)
(8W-30-20)
(8W-30-2)
(8W-30-6)
(8W-30-20)
(8W-12-2)
(8W-12-13)
(8W-10-16)
GAS
NS/GS
J988W-3 GS001026
FUEL
HEATER
1
WT/BK
18
F87
A141
18
DG/WT
4
B33
E120
BATTERY
Z0
2
BK BK
8
Z0 Z0
10
BK
G103 G100 ES01
BK
20
Z1
BATT A0
20A
FUSE
16
CENTER
DISTRIBUTION
POWER
RELAY
HEATER
FUEL
C2
7
DG/WT
16
A141
85 87
30 86
3
C6
BLOCK
JUNCTION
30
C1
9A
1
PTC
ST-RUN A21
6 C2
F87
18
WT/BK
(DIESEL)
38
CONTROL
POWERTRAIN
MODULE
C6
6
SENSOR
VEHICLE
SPEED
1
F87
18
WT/BK
1
ES40
A141
18
DG/WT
A141
18
DG/WT
CRANK
CASE
HEATER
(8W-30-29)
(8W-20-3)
(8W-15-3)
(8W-10-8)
(8W-10-9)
(8W-12-2)
(8W-12-13)
(8W-10-16)
(8W-30-36)
(8W-30-36)
(8W-30-29)
DIESEL
8W - 10 - 27
GS001027 J988W-3
C8
4 3
C8
T15
18
LG
15
85 87
30 86
BATT A0
CENTER
DISTRIBUTION
POWER
ES01
RD
18
T16 T16
18
RD RD
18
T16
16
T16
18
RD
MODULE
CONTROL
TRANSMISSION
RD/DB
18
A5
56 17
C8
2 10
C8
RELAY
CONTROL
TRANSMISSION
20A
FUSE
15
TRANSMISSION
CONTROL
4
SOLENOIDS
BATTERY
ES11
G100
G103
Z0
6
BK
Z0
8
BK
Z0
10
BK
Z16
18
BK
(8W-10-8)
(8W-10-9)
(8W-31-2)
(8W-31-6)
(8W-31-7)
(8W-20-2)
(8W-15-2)
GAS
NS/GS
J988W-3 GS001028
BATT A0
20A
FUSE
13
CENTER
DISTRIBUTION
POWER
8
C3
F32
18
PK/DB
11
FUSE
15A
A/C
COMPRESSOR
CLUTCH
SWITCH
6
LAMP
STOP
2
C6
DB/BK
18
C3
CONTROLLER
ANTI-LOCK
BRAKE
RD/DB
12
A20
C3
6
12
FUSE
25A
9
RELAY
1
CLUTCH
COMPRESSOR
A/C
20A
FUSE
10
C5
9
L9
18
BK/WT
C2 27
BLOCK
JUNCTION
1
MODULE
DRL
FLASHER/
COMBINATION
BATT A0
ST-RUN A21
PTC
1
9A
C1
30
JUNCTION
BLOCK
WT/BK
18
F87
C2 6
86 30
87 85
C6
7
C2 64
MODULE
CONTROL
POWERTRAIN
6 C6 C6 1
ES07
F87
18
WT/BK
F87
18
BK/WT
C13
20
DB/OR
POWERTRAIN
CONTROL
MODULE
28
9
E97
B106
C13
18
DB/OR
DIESEL GAS
38
MODULE
CONTROL
POWERTRAIN
(DIESEL)
F87 18 WT/BK
DIESEL GAS
VEHICLE
SPEED
SENSOR
1
30
87
DIESEL
POWER
RELAY
20A
FUSE
17
BATT A0
CENTER
DISTRIBUTION
POWER
5
C6
DIESEL GAS
ES06
ES29
A142 18DG/OR
(8W-10-8)
(8W-10-10)
(8W-33-5)
(8W-51-7)
(8W-35-2) (8W-42-7)
(8W-42-9)
(8W-12-2)
(8W-50-11)
(8W-50-12)
(8W-10-8)
(8W-10-16)
(8W-12-13)
(8W-12-2)
(8W-30-5)
(8W-12-13)
(8W-30-37)
(8W-30-36)
(8W-30-36)
(8W-30-28)
(8W-10-25)
(8W-10-8)
(8W-10-9)
(8W-10-25)
(8W-10-25)
(8W-12-13)
GS001029 J988W-3
BATT A0
CENTER
DISTRIBUTION
POWER
9
FUSE
20A
85 87
30 86
HORN
NOTE
LOW
A
HORN
RELAY
X3
20
BK/RD
CLOCKSPRING
8
C2 C2
4
X2
18
DG/RD
HORN
NOTE
HIGH
A
BS19
X2
18
DG/RD
X2
18
DG/RD
GY/OR
20
X4
JUNCTION
BLOCK
4 C2
CONTROL
RELAY
HORN
18
MODULE
BODY
CONTROL
20
C2
RELAY
CONTROL
1 C2
HORN
X3
20
BK/RD
HORN
SWITCH
(8W-10-8)
(8W-10-10)
(8W-41-2)
(8W-41-2)
(8W-41-2)
(8W-12-2)
(8W-45-3)
J988W-3 GS001030
BATT A0
CENTER
DISTRIBUTION
POWER
8
FUSE
20A
85 87
30 86
10
C2
F30
16
RD
ACCESSORY
CIGAR/
RELAY
A22
22
B23
P34
1
OUTLET
POWER
LIGHTER/
CIGAR
REAR
1
C4
2
Z1
18
BK
F30
16
RD
F30
16
RD
G300
10
JUNCTION
BLOCK
9A
7
PTC
16
C2
9 C2
RUN-ACC A31
F1
20
DB
FRONT
CIGAR
LIGHTER/
POWER
OUTLET
(8W-10-8)
(8W-10-10)
(8W-41-3)
(8W-41-3)
(8W-15-7)
(8W-12-2)
(8W-12-16)
(8W-10-16)
(8W-41-3)
GS001031 J988W-3
85 87
30 86
HIGH
BEAM
RELAY
POWER
DISTRIBUTION
CENTER
BATT A0
RELAY
BEAM
LOW
87 85
10A
FUSE
5
10A
FUSE
4 7
FUSE
15A
6
FUSE
20A
C3
7 2
C3
P18
B23
20
B20 B21
21
L94
20
OR/WT
L94
20
OR/WT
L324
20
WT/LG
L324
22
WT/LG
9
10
8
12
HEADLAMP
DIMMER
G200
13
12
33 C3
15
BLOCK
JUNCTION
COMBINATION
FLASHER/
DRL
MODULE
MODULE
CONTROL
BODY
CONTROL
RELAY
BEAM
HIGH/LOW
L93
22
PK
86 30
HEADLAMP
SENSE
SWITCH
(PART OF
MULTI-
FUNCTION
SWITCH)
CHRYSLER
DODGE/
PYLMOUTH
L193
20
OR/WT
Z1
18
BK
76 C1
(8W-10-10)
(8W-10-8)
(8W-10-33)
(8W-10-34)
(8W-10-33)
(8W-10-34)
(8W-10-33)
(8W-10-34)
(8W-10-33)
(8W-10-34)
(8W-15-4)
(8W-12-2)
(8W-45-5)
(8W-50-2)
J988W-3 GS001032
85 87
30 86
6
C5
POWER
DISTRIBUTION
CENTER
C3
1
BATT A0
87 85
10A
FUSE
5
10A
FUSE
4 7
FUSE
15A
6
FUSE
20A
1
C5 C5
8
L44
20
VT/RD
L43
18
VT
L33
20
RD
L34
20
RD/OR
86 30
DODGE/
PYLMOUTH CHRYSLER CHRYSLER PYLMOUTH
DODGE/
CHRYSLER PYLMOUTH
DODGE/
CHRYSLER PYLMOUTH
DODGE/
TO
BS15 LEFT
HEADLAMP
TO TO
HEADLAMP
HIGH
LEFT
RIGHT
LOW
HEADLAMP
TO
TO
HEADLAMP
RIGHT
1
CENTER
MESSAGE
RIGHT
HEADLAMP
TO TO
HEADLAMP
HIGH
RIGHT
18
B23
P18
B18
L34
20
RD/OR
L34
20
RD/OR
L33
20
RD
L33
20
RD
L44
20
VT/RD
L44
20
VT/RD
L43
18
VT
L43
18
VT
L34
20
RD/OR
L34
20
RD/OR
LOW
BEAM
RELAY RELAY
BEAM
HIGH
FOG
LAMP
RELAY
(IN JB)
TO
(8W-10-10)
(8W-10-8)
(8W-50-6)
(8W-50-6)
(8W-50-5)
(8W-50-4)
(8W-50-6)
(8W-50-8)
(8W-46-4)
(8W-50-6)
(8W-50-8)
(8W-50-4)
(8W-50-2) (8W-50-2)
(8W-50-5)
8W - 10 - 33
GS001033 J988W-3
85 87
30 86
6
C5
POWER
DISTRIBUTION
CENTER
C3
1
BATT A0
87 85
10A
FUSE
5
10A
FUSE
4 7
FUSE
15A
6
FUSE
20A
1
C5 C5
8
L44
20
VT/RD
L43
18
VT
L33
20
RD
L34
20
RD/OR
86 30
1
CENTER
MESSAGE
18
B23
P18
B18
L34
20
RD/OR
L34
20
RD/OR
LOW
BEAM
RELAY RELAY
BEAM
HIGH
* RHD
*6
2 1
HEADLAMP
LEFT
RIGHT
HEADLAMP
1 2 2
HEADLAMP
SWITCH
B3 B23
3
MOTOR
LEVELING
HEADLAMP
LEFT
RIGHT
HEADLAMP
LEVELING
MOTOR
3
BS16
P18 3
L44
20
VT/RD
L44
20
VT/RD
L44
20
VT/RD
L44
20
VT/RD
L44
20
VT/RD
C1
(8W-10-10)
(8W-10-8)
(8W-46-4)
(8W-50-2) (8W-50-2)
(8W-50-6)
(8W-50-8) (8W-50-10)
(8W-50-8)
(8W-50-8)
BUILT-UP-EXPORT
NS/GS
J988W-3 GS001034
ST-RUN A21
CENTER
DISTRIBUTION
POWER
2
FUSE
10A
2
C5
10A
FUSE
1
C5
10
23
B23
F14
18
LG/YL
MODULE
CONTROL
AIRBAG
1 C2 C2 2
JUNCTION
BLOCK
C2 6 1 C4
B24
24
B23
P18
F23
18
DB/YL
31
C2
9A
1
PTC
C1
30
RUN A22
F87
18
WT/BK
A22
12
BK/OR
-EXPORT
F14
18
LG/YL
F14
20
LG/YL
BUILT-UP
-UP-EXPORT
EXCEPT BUILT EXCEPT BUILT
-UP-EXPORT -EXPORT
BUILT-UP
DB/YL
20
F23
DB/YL
18
F23
(8W-10-16)
(8W-10-8)
(8W-43-2)
(8W-12-2)
(8W-12-13)
(8W-10-14)
(8W-10-14)
GS001035 J988W-3
8W-12 J UNCTION BLOCK
Component Page
A/C Compressor Cl utch Rel ay . . . . . . . . . . . . . .8W-12-13
A/C Heater Control . . . . . . . . . . . . . . . . .8W-12-9, 12, 23
Ai rbag Control Modul e . . . . . . . . . . . . . . . . . . .8W-12-13
Ash Recei ver Lamp . . . . . . . . . . . . . . . . . . .8W-12-19, 23
Automati c Day/Ni ght Mi rror . . . . . . . . . . . . . . . .8W-12-9
Back-Up Swi tch . . . . . . . . . . . . . . . . . . . . . . . .8W-12-12
Body Control Modul e . . . . . . . .8W-12-8, 9, 14, 15, 17, 18,
19, 20, 22, 23, 24, 26
Brake Pressure Swi tch . . . . . . . . . . . . . . . . . . .8W-12-17
Ci gar/Accessory Rel ay. . . . . . . . . . . . . . . . . . . .8W-12-16
Cl utch I nterl ock Swi tch . . . . . . . . . . . . . . . . . .8W-12-16
Cl utch I nterl ock Swi tch Jumper . . . . . . . . . . . .8W-12-16
Combi nati on Fl asher/DRL Modul e . . .8W-12-12, 17, 18, 19
Control l er Anti -Lock Brake . . . . . . . . . . . . . . . .8W-12-12
Courtesy Lamp Rel ay . . . . . . . . . . . . . . . . . . . .8W-12-22
CS01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-22
CS02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-21
CS04 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-9
CS1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-22
Data Li nk Connector . . . . . . . . . . . . . . . . . . . .8W-12-20
Door Lock Rel ay . . . . . . . . . . . . . . . . . . . . .8W-12-15, 19
Door Unl ock Rel ay . . . . . . . . . . . . . . . . . . .8W-12-14, 19
Dri ver Door Courtesy Lamp . . . . . . . . . . . . . . .8W-12-22
Dri ver Door Lock Motor . . . . . . . . . . . . . . . .8W-12-14, 15
Dri ver Door Lock Swi tch. . . . . . . . . . . . . . . . . .8W-12-23
Dri ver Door Unl ock Rel ay . . . . . . . . . . . . . .8W-12-14, 19
Dri ver Heated Seat Swi tch . . . . . . . . . . . . . . . .8W-12-12
Dri ver Power Mi rror . . . . . . . . . . . . . . . . . .8W-12-10, 26
Dri ver Power Wi ndow Swi tch . . . . . . . . . . . .8W-12-16, 23
EGR Sol enoi d . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-13
El ectri c Wi per De-I cer . . . . . . . . . . . . . . . . . . .8W-12-11
Engi ne Starter Motor Rel ay . . . . . . . . . . . . . . .8W-12-16
ES07 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-13
ES29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-13
Evap Leak Detecti on Pump . . . . . . . . . . . . . . . .8W-12-13
Fog Lamp Rel ay . . . . . . . . . . . . . . . . . . . . . . .8W-12-25
Front Bl ower Motor Rel ay . . . . . . . . . . . . . . . . .8W-12-12
Front Ci gar Li ghter/Power Outl et . . . . . . . . . . .8W-12-23
Front Readi ng Lamps/Swi tch . . . . . . . . . . . . . .8W-12-21
Front Washer Motor . . . . . . . . . . . . . . . .8W-12-16, 23, 24
Front Wi per Swi tch . . . . . . . . . . . . . . . .8W-12-16, 23, 24
Fuel Heater Rel ay . . . . . . . . . . . . . . . . . . . . . .8W-12-13
Fuel Pump Rel ay . . . . . . . . . . . . . . . . . . . . . . .8W-12-13
Fuse 1 (JB). . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-8
Fuse 2 (JB) . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-9, 20
Fuse 2 (PDC). . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-13
Fuse 3 (JB). . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-8
Fuse 4 (JB). . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-8
Fuse 5 (JB) . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-8, 24
Fuse 6 (JB). . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-9
Fuse 6 (PDC). . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-25
Fuse 7 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-10
Fuse 8 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-11
Fuse 9 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-11
Fuse 10 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-16
Fuse 11 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-11
Fuse 12 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-12
Fuse 18 (PDC). . . . . . . . . . . . . . . . . . . . . . . . .8W-12-26
Fuse 22 (PDC) . . . . . . . . . . . . . . . . . . . . . . .8W-12-8, 24
G300 . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-11, 19, 26
Gl ove Box Lamp . . . . . . . . . . . . . . . . . . . . . . .8W-12-21
Headl amp Di mmer Swi tch . . . . . . . . . . . . . .8W-12-18, 25
Headl amp Swi tch . . . . . . . . . . . . .8W-12-8, 19, 22, 23, 25
Headl amp Washer . . . . . . . . . . . . . . . . . . . . . .8W-12-24
Horn Rel ay . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-17
HS2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-12
HS4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-12
Component Page
I gni ti on Swi tch . . . . . . . . . . . . . . . . . . .8W-12-17, 19, 20
I nstrument Cl uster . . . . . . . . . . . . . .8W-12-9, 19, 20, 23
Juncti on Bl ock . . . . . .8W-12-2, 8, 9, 10, 11, 12, 13, 14, 15,
16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26
Key-I n Hal o Lamp . . . . . . . . . . . . . . . . .8W-12-19, 22, 26
Left Combi nati on Rel ay . . . . . . . . . . . . . . . . . .8W-12-18
Left Fog Lamp . . . . . . . . . . . . . . . . . . . . . . .8W-12-8, 25
Left Front Park/Turn Si gnal Lamp . . . . . . . . .8W-12-8, 18
Left Li ftgate Fl ood Lamp . . . . . . . . . . . . . . . . .8W-12-22
Left Low Headl amp . . . . . . . . . . . . . . . . . . . . .8W-12-25
Left Rear Lamp Assembl y . . . . . . . . . . . . . . .8W-12-8, 18
Left Rear Sl i di ng Door Contact. . . . . . . . . . .8W-12-14, 15
Left Repeater Lamp . . . . . . . . . . . . . . . . . . . . .8W-12-18
Left Stop/Turn Si gnal Rel ay . . . . . . . . . . . . . . .8W-12-18
Li cense Lamp . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-8
Li ftgate Lock Motor . . . . . . . . . . . . . . . . . .8W-12-14, 15
Low Beam Rel ay . . . . . . . . . . . . . . . . . . . . . . .8W-12-25
Message Center . . . . . . . . . . . . . .8W-12-9, 17, 18, 19, 20
Name Brand Speaker Rel ay . . . . . . . . . . . . .8W-12-11, 19
Overhead Consol e . . . . . . . . . . . . . . . . . . . . . . .8W-12-9
Park Brake Swi tch . . . . . . . . . . . . . . . . . . . . . .8W-12-17
Park Lamp Rel ay . . . . . . . . . . . . . . . . . . . . .8W-12-8, 24
Passenger Door Courtesy Lamp . . . . . . . . . . . . .8W-12-22
Passenger Door Lock Motor . . . . . . . . . . . . .8W-12-14, 15
Passenger Door Lock Swi tch . . . . . . . . . . . . . . .8W-12-23
Passenger Heated Seat Swi tch. . . . . . . . . . . . . .8W-12-12
Passenger Power Mi rror . . . . . . . . . . . . . . .8W-12-10, 26
Passenger Power Wi ndow Swi tch . . . . . . . . .8W-12-16, 23
Power Di stri buti on Center . . . . . . . . .8W-8, 12-12, 13, 16,
17, 24, 25, 26
Power Fol di ng Mi rror Swi tch . . . . . . . . . . . .8W-12-19, 26
Power Mi rror Fol d Rel ay. . . . . . . . . . . . . . . . . .8W-12-26
Power Mi rror Swi tch . . . . . . . . . . . . . . .8W-12-19, 21, 23
Power Mi rror Unfol d Rel ay . . . . . . . . . . . . . . . .8W-12-26
Powertrai n Control Modul e . . . . . . . . . . . . . . . .8W-12-13
PTC 1 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-13
PTC 3 (JB) . . . . . . . . . . . . . . . . . . . . . .8W-12-14, 15, 24
PTC 7 (JB). . . . . . . . . . . . . . . . . . . . . . . . .8W-12-16, 24
PTC 8 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-16
PTC 9 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-16
Radi o . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-11, 20, 23
Radi o Choke . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-11
Rear A/C Heater Uni t . . . . . . . . . . . . . . . . . . . .8W-12-11
Rear Bl ower Front Control Swi tch . . . . . . . . . . .8W-12-23
Rear Bl ower Rear Control Swi tch . . . . . . . . . . .8W-12-23
Rear Washer Motor . . . . . . . . . . . . . . . . . . . . .8W-12-16
Rear Wi ndow Defogger . . . . . . . . . . . . . . . . . . .8W-12-10
Rear Wi ndow Defogger Rel ay . . . . . . . . . . . .8W-12-10, 12
Rear Wi per Motor . . . . . . . . . . . . . . . . . . . . . . .8W-12-9
Remote Keyl ess Entry Modul e . . . . . . . . . . . . . .8W-12-20
Ri ght Combi nati on Rel ay . . . . . . . . . . . . . . . . .8W-12-18
Ri ght Fog Lamp . . . . . . . . . . . . . . . . . . . . . .8W-12-8, 25
Ri ght Front Park/Turn Si gnal Lamp . . . . . . . .8W-12-8, 18
Ri ght Li ftgate Fl ood Lamp . . . . . . . . . . . . . . . .8W-12-22
Ri ght Rear Lamp Assembl y . . . . . . . . . . . . . .8W-12-8, 18
Ri ght Rear Sl i di ng Door Contact. . . . . . . . . .8W-12-14, 15
Ri ght Repeater Lamp . . . . . . . . . . . . . . . . . . . .8W-12-18
Ri ght Stop/Turn Si gnal Rel ay . . . . . . . . . . . . . .8W-12-18
Sentry Key I mmobi l i zer Modul e . . . . . . . . . .8W-12-13, 21
Stop Lamp Swi tch . . . . . . . . . . . . . . . . . . . . . .8W-12-19
Tracti on Control Swi tch . . . . . . . . . . . . . . . .8W-12-19, 23
Trai l er Tow Connector . . . . . . . . . . . . . . . . . . . .8W-12-8
Transmi ssi on Control Modul e. . . . . . . . . . . . .8W-12-9, 16
Transmi ssi on Range Sensor . . . . . . . . . . . . . . . .8W-12-12
Turn Si gnal /Hazard Swi tch . . . . . . . . . . . . . . . .8W-12-17
Uni versal Garage Door Opener . . . . . . . . . . . . .8W-12-23
Washer Modul e . . . . . . . . . . . . . . . . .8W-12-8, 15, 16, 23
NS/GS 8W - 12 JUNCTION BLOCK 8W - 12 - 1
87
85 86
30
1
JUNCTION BLOCK
TOP OF
2 3 4 5 6 7 8 9 10 11 12
6
FUSES
7 8 9 10 5 4 3 2 1
PTCS
87A 87A
30
86 85
87
87A
30
86 85
87
87
85
86
30
30
86
85
87
87
85
86
30
12
10 11
2 9 8
4
5
1 3
7 6
1
2
1
2 1
2
2
1
DOOR UNLOCK
RELAY RELAY
DOOR LOCK COMBINATION FLASHER/
DRL MODULE
RELAY
DOOR UNLOCK
DRIVER
D3
D1
D4
D2
COURTESY
LAMP RELAY
REAR WINDOW
DEFOGGER RELAY
SPEAKER RELAY
NAME BRAND
1
8
15
19
23
30
2 3 4 5 6 7
14 13 12 11 10 9
16
20 21 22
18 17
29
36 35 34 33 32 31
24 25 26 27 28
28 27 26 25 24
31 32 33 34 35 36
29
17 18
22 21 20
16
9 10 11 12 13 14
7 6 5 4 3 2
30
23
19
15
8
1
28 27 26 25 24
31 32 33 34 35 36
29
17 18
22 21 20
16
9 10 11 12 13 14
7 6 5 4 3 2
30
23
19
15
8
1
28 27 26 25 24
31 32 33 34 35 36
29
17 18
22 21 20
16
9 10 11 12 13 14
7 6 5 4 3 2
30
23
19
15
8
1
C1
C4
C3
C2
87
85 86
30
87A
87
85 86
30
87A
FOLD RELAY
POWER MIRROR
UNFOLD RELAY
POWER MIRROR WASHER
MODULE
P
S 31
30
56
87A
87A
87A
8W - 12 - 2 8W-12 JUNCTION BLOCK NS/GS
J988W-3 GS001202
FUSES
FUSE NO. AMPS FUSED CIRCUIT FEED CIRCUIT
1
10A INTERNAL
L78 20DG/YL
F11 20RD/WT
2
3
L78 20DG/YL
4
5
6
INTERNAL
7
C16 20LB/YL
8
10
C40 12BR/WT
9
F45 20YL/RD
INTERNAL
11
12
A81 20DG/RD
L7 12BK/YL
L7 12BK/YL
INTERNAL
INTERNAL
A41 12YL
A22 12BK/OR
10A
15A
15A
15A
20A
10A
10A
10A
20A
10A
INTERNAL L7 12BK/YL
INTERNAL V20 18RD 15A
A21 12DB
A22 12BK/OR
-
9A
-
-
9A
9A
-
-
-
9A
-
-
-
-
-
9
10
8
7
-
6
5
4
-
3
2
-
INTERNAL 9A
1
FEED CIRCUIT FUSED CIRCUIT AMPS PTC NO.
(POSITIVE TEMPERATURE COEFFICIENT)
PTCS
F21 12TN
-
FOG LAMPS
F39 18PK/LG
INTERNAL
A21 12DB
INTERNAL
INTERNAL
INTERNAL
INTERNAL
INTERNAL
INTERNAL
INTERNAL
INTERNAL
L78 20DG/YL
L78 20DG/YL
F39 18PK/LG
C16 20LB/YL
NS/GS 8W-12 JUNCTION BLOCK 8W - 12 - 3
GS001203 J988W-3
1
2
3
4
FUSED B (+) L9 18BK/WT
L61 18LG LEFT FRONT TURN SIGNAL
L60 18TN RIGHT FRONT TURN SIGNAL
INTERNAL LEFT REAR TURN SIGNAL
HIGH/LOW BEAM RELY CONTROL
GROUND
RED BRAKE WARNING LAMP SENSE
12
11
10
DOOR LOCK RELAY CONTROL
FUSED B (+)
FUSED B (+)
GROUND
87A
DOOR LOCK RELAY
30
85
86
87
DOOR LOCK RELAY OUTPUT INTERNAL
COMBINATION FLASHER/DRL MODULE
RIGHT REAR TURN SIGNAL
5
FUSED IGNITION (RUN)
6
LEFT TURN SIGNAL SENSE L305 22LB/WT
7
RIGHT TURN SIGNAL SENSE L302 22LB/YL
8
COMBINATION FLASHER SWITCHED GROUND
L91 20DB/PK
9
COURTESY LAMP RELAY CONTROL
- -
-
COURTESY LAMP RELAY
30
85
86
87
INTERNAL
M111 22BR/WT
FUSED B (+)
FUSED B (+)
COURTESY LAMP RELAY OUTPUT
INTERNAL
INTERNAL
INTERNAL
INTERNAL
INTERNAL
INTERNAL
INTERNAL
INTERNAL
INTERNAL
INTERNAL
INTERNAL
L91 22DB/PK
J988W-3 GS001204
NAME BRAND SPEAKER RELAY OUTPUT
GROUND
NAME BRAND SPEAKER RELAY DRIVER
- -
-
NAME BRAND SPEAKER RELAY
30
85
86
87
X60 20RD/DG
X1 16DG/RD
FUSED IGNITION (RUN-ACC)
LEFT FRONT DOOR UNLOCK RELAY CONTROL
FUSED B (+)
FUSED B (+)
GROUND
87A
DRIVER DOOR UNLOCK RELAY
30
85
86
87
LEFT FRONT DOOR UNLOCK RELAY OUTPUT F131 20BK/PK
DOOR UNLOCK RELAY CONTROL
FUSED B (+)
FUSED B (+)
GROUND
87A
DOOR UNLOCK RELAY
30
85
86
87
DOOR UNLOCK RELAY OUTPUT INTERNAL
INTERNAL
INTERNAL
INTERNAL
INTERNAL
INTERNAL
INTERNAL
INTERNAL
INTERNAL
INTERNAL
INTERNAL
* CHRYSLER
FUSED LOW BEAM RELAY OUTPUT
87A
FOG LAMP RELAYCONTROL
- -
FOG LAMP RELAY*
30
85
86
87
INTERNAL
L94 20OR/WT
FOG LAMP RELAY OUTPUT
INTERNAL
INTERNAL
GS001205 J988W-3
REAR WINDOW DEFOGGER RELAY CONTROL
- -
-
REAR WINDOW DEFOGGER RELAY
30
85
86
87
A4 12BK/RD
C14 22WT/RD
INTERNAL
INTERNAL
FUSED B (+)
REAR WINDOW DEFOGGER RELAY OUTPUT
FUSED B (+)
INTERNAL
P174 20YL/RD
P159 20DG
87
86
85
30
(BUILT-UP-EXPORT)
P159 20DG
FUSED B (+)
INTERNAL
87A
INTERNAL GROUND
POWER MIRROR UNFOLD OUTPUT
POWER MIRROR UNFOLD OUTPUT
POWER MIRROR FOLD OUTPUT
POWER MIRROR FOLD OUTPUT
GROUND INTERNAL
87A
INTERNAL
FUSED B (+)
P160 20LB
(BUILT-UP-EXPORT)
30
85
86
87
P160 20LB
P171 20VT/WT
INTERNAL
FUSED B (+)
POWER MIRROR FOLD RELAY
POWER MIRROR UNFOLD RELAY
J988W-3 GS001206
ANODE (+)
2
1
D4
ORIENTATION CAVITY CIRCUIT
CATHODE
CATHODE
CIRCUIT CAVITY ORIENTATION
D3
1
2
ANODE (+)
CATHODE
CIRCUIT CAVITY ORIENTATION
(NOT USED)
1
2
ANODE (+) -
-
DIODES
INTERNAL ANODE (+)
2
1
D1
ORIENTATION CAVITY CIRCUIT
CATHODE
D2
WASHER MODULE CONTROL
FUSED PARK LAMP RELAY OUTPUT
(BUILT-UP-EXPORT)
30
31
56
P
V53 18RD/YL
INTERNAL
INTERNAL
INTERNAL
WASHER MODULE OUTPUT
FUSED B(+)
WASHER MODULE
S
INTERNAL FUSED IGNITION (RUN-ACC)
INTERNAL
INTERNAL
INTERNAL
INTERNAL
INTERNAL
GS001207 J988W-3
BATT A0
40A
FUSE
22
CENTER
DISTRIBUTION
POWER
10
C3
85 87
30 86
RELAY
LAMP
PARK
C1
4
BLOCK
JUNCTION
C2 9 2 C1
16
3
FUSE
15A
L7
12
BK/YL
BODY
CONTROL
MODULE
L97
18
PK/DB
15A
FUSE
5
1
10A
FUSE
1
C1
23 5
C1
18
C1
L78
20
DG/YL
L78
20
DG/YL
2
TURN
PARK/
FRONT
RIGHT
RIGHT
REAR
LAMP
ASSEMBLY
4 LEFT
FRONT
PARK/
TURN
LAMP
2
BR/YL
20
L77
L77
20
BR/LB
L77
20
BR/LB
4
ASSEMBLY
LAMP
REAR
LEFT
2
LAMP
LICENSE
L77
20
BR/LB
LJ01
B17
5
L15
J02A
6
T05
B99
4
T08
B98
4
L78
20
DG/YL
TRAILER
TOW OTHERS
2
TRAILER
TOW
CONNECTOR
L78
18
BR
L77
20
BR/LB
L77
20
BR/LB
OTHERS TOW
TRAILER
SIGNAL
SIGNAL
LAMP
WASHER
MODULE
(BUILT-UP
-EXPORT)
C2 5
-EXPORT)
(BUILT-UP
SWITCH
HEADLAMP
28
B23
P18
B28
L77
18
BR/YL
*1
*3
*1
*3
4
FUSE
15A
C1 3
1
1
-EXPORT)
(BUILT-UP
LAMP
FOG
LEFT
RIGHT
FOG
LAMP
(BUILT-UP
-EXPORT)
F39
18
PK/LG
F39
18
PK/LG
* BUILT-UP-EXPORT
56
(8W-10-8)
(8W-10-8)
(8W-12-2)
(8W-45-3)
(8W-10-17)
(8W-51-4)
(8W-51-5)
(8W-51-6)
(8W-50-11)
(8W-50-12)
(8W-51-4)
(8W-51-5)
(8W-51-6)
(8W-51-2)
(8W-54-2)
(8W-50-11)
(8W-50-12)
(8W-53-5)
(8W-50-10)
(8W-50-7)
(8W-50-7)
J988W-3 GS001208
ST-RUN-OFF A81
10A
FUSE
2
11
CLUSTER
INSTRUMENT
BLOCK
JUNCTION
10
C4
D1
6
FUSE
20A
ST-RUN A21
7
BODY
CONTROL
MODULE
12 11
C1
20 14
C4
7
C1
F11
20
RD/WT
20
F11
RD/WT
E36
B33
8
F11
18
RD/WT
TRANSMISSION
CONTROL
11
MODULE
MESSAGE
CENTER
10
D3
V23
18
BR/PK
10
CONTROL
A/C
C1
V23
18
BR/PK
V23
18
BR/PK
V23
18
BR/PK
REAR
WIPER
2
MOTOR
L16
J03A
3
LJ01
B17
8
HEATER
1
AUTOMATIC
DAY/NIGHT
MIRROR
C1
14
11
B75
C20
1
C19
EC1
V23
18
BR/PK
V23
18
BR/PK
13
CS04
COMPASS/
MINI-TRIP
COMPUTER
CONSOLE
OVERHEAD
4
V23
18
BR/PK
F11
20
RD/WT
4 P50
NOT
USED
V23
18
BR/PK
(8W-10-16)
(8W-40-2)
(8W-12-2)
(8W-10-16)
(8W-45-2)
(8W-31-5)
(8W-46-2)
(8W-42-4)
(8W-53-4)
(8W-44-6)
(8W-49-2)
GS001209 J988W-3
BATT A4
JUNCTION
BLOCK
30
87
6
C1
REAR
WINDOW
DEFOGGER
RELAY
10A
FUSE
7
C4
20
DEFOGGER
WINDOW
REAR
C15
12
BK/WT
12
B17
LJ01
C15
12
BK/WT
L16
J03A
1
C15
12
BK/WT
C16
20
LB/YL
C16
20
LB/YL
4
PASSENGER
POWER
MIRROR
MIRROR
POWER
DRIVER
4 C1
C1
(8W-10-12)
(8W-12-2)
(8W-48-2)
(8W-48-2)
(8W-48-2)
(8W-48-2)
J988W-3 GS001210
RUN-ACC A31
JUNCTION
BLOCK
22
C1
NAME
BRAND
SPEAKER
RELAY
10A
FUSE
8
CHOKE
RADIO
1
X1
16
DG/RD
RADIO)
(PREMIUM
85 87
30 86
C2
2
G300
8
13
C3
BK
14
Z1
C3
24
C1 6
RADIO
1 C2
X12
18
RD/WT
X60
20
RD/DG
20A
FUSE
11
RUN A22
C2
12
C40
12
BR/WT
UNIT
A/C
REAR
3
HEATER
9
FUSE
15A
15
C3
ELECTRIC
WIPER
DE-ICER
V20
18
RD
X12
20
RD/WT
6 P50
NOT
USED
1 C1
(8W-10-16)
(8W-12-2)
(8W-47-4)
(8W-15-6)
(8W-47-2)
(8W-47-4)
(8W-10-14)
(8W-42-6)
(8W-48-3)
(8W-12-19)
GS001211 J988W-3
JUNCTION
BLOCK
12
FUSE
10A
RUN A22
C2
14 18
C2
7
C2
COMBINATION
FLASHER/
DRL
MODULE
32
C4
REAR
WINDOW
DEFOGGER
RELAY
86
85
CONTROL
A/C
1 C1
SENSOR
RANGE
TRANSMISSION
1
86
RELAY
MOTOR
BLOWER
FRONT CENTER
DISTRIBUTION
POWER
C2 5
C14
22
WT/RD
F20
20
WT
F20
20
WT
F20
20
WT
F20
18
WT
F20
20
WT
E36
B33
5
F20
20
WT
4
B09
HS5D
6
HEATER
HS2
F20
20
WT
F20
20
WT
23
BRAKE
ANTI-LOCK
CONTROLLER
F20
18
WT
HS4
F20
20
WT
F20
20
WT
HS5P
B56
4
D B
SWITCH
SEAT
HEATED
DRIVER
PASSENGER
HEATED
SEAT
SWITCH
B D
EATX MTX
GAS DIESEL
B33
5 E36
5
E120
B33
F20
20
WT
F20
18
WT
1
SWITCH
BACK-UP
F20
20
WT
F20
20
WT
85
(8W-12-2)
(8W-10-14)
(8W-51-3)
(8W-48-2)
(8W-42-4)
(8W-31-3)
(8W-42-2)
(8W-10-8)
(8W-35-2)
(8W-63-7)
(8W-63-8)
(8W-51-5)
J988W-3 GS001212
JUNCTION
BLOCK
1
PTC
9A
ST-RUN A21
C1
30
F87
18
WT/BK
POWER
DISTRIBUTION
CENTER
6 C2
6
C6 C6
1
F87
18
F87
18
ES07
10A
FUSE
2
FUEL
PUMP
86
RELAY
86
RELAY
CLUTCH
COMPRESSOR
A/C
C1 20
POWERTRAIN
CONTROL
MODULE
DETECTION
LEAK
EVAP
PUMP
3
2
F87
18
F87
18
F87
18
WT/BK BK/WT
WT/BK
WT/BK
WT/BK
38
(DIESEL)
MODULE
CONTROL
POWERTRAIN
F87
18
WT/BK
19
C4
3
-EXPORT)
(BUILT-UP
MODULE
IMMOBILIZER
KEY
SENTRY
F87
20
WT/BK
EGR
SOLENOID
(EXCEPT BUILT-
UP-EXPORT)
2
C5
-EXPORT
BUILT-UP
UP-EXPORT
EXCEPT BUILT-
F14
18
LG/YL
F14
20
LG/YL
1
AIRBAG
CONTROL
MODULE
F14
18
LG/YL
B23 B23
P18 23
FUEL
HEATER
RELAY
(DIESEL)
85
86
85
85
GAS DIESEL
1
C6
TO
ES29
C2
A142
18
DG/OR
(GAS)
(8W-12-2)
(8W-10-16)
(8W-10-9)
(8W-10-10)
(8W-10-35)
(8W-30-6)
(8W-30-20)
(8W-42-7)
(8W-42-9)
(8W-30-36)
(8W-39-5)
(8W-30-20)
(8W-30-18)
(8W-30-26)
(8W-30-2)
(8W-43-2)
(8W-30-29)
(8W-10-25)
GS001213 J988W-3
BATT A2
JUNCTION
BLOCK
30
87 86
RELAY
UNLOCK
DOOR
30
87 86
DOOR
DRIVER
UNLOCK
RELAY
(RKE)
C1
9 15
C1 C1
19
1
MOTOR
LOCK
DOOR
DRIVER PASSENGER
DOOR
LOCK
MOTOR
1
CONTACT
DOOR
SLIDING
REAR
RIGHT
3
LEFT
REAR
SLIDING
DOOR
CONTACT
D01D
B02
5
F131
20
BK/PK
F131
20
BK/PK
F136
20
VT/YL
F136
20
VT/YL
B03
D01P
9
F136
20
VT/YL
F136
20
VT/WT
F136
20
VT/WT
F136
20
VT/WT
F136
20
VT/WT
10
B17
LJ01
5
J02A
L15
2 2
9A
PTC
3
RKE OTHER
LIFTGATE
LOCK
MOTOR
85 85
5
BODY
CONTROL
MODULE
6
87A 87A
(8W-10-13)
(8W-12-2)
(8W-61-3)
(8W-61-4)
(8W-61-7)
(8W-61-8)
(8W-61-7)
(8W-61-8)
(8W-61-3)
(8W-61-7)
(8W-61-3)
(8W-61-7)
(8W-61-4)
(8W-61-8)
(8W-61-4)
(8W-61-8)
(8W-61-3)
(8W-61-7)
(8W-45-7)
(8W-10-13)
J988W-3 GS001214
JUNCTION
BLOCK
DOOR
LOCK
RELAY
86 87
30
BATT A2
32
C1 C1
11 26
C1
2
MOTOR
LOCK
DOOR
PASSENGER
DRIVER
DOOR
LOCK
MOTOR
2
RIGHT
REAR
SLIDING
DOOR
CONTACT
SLIDING
REAR
LEFT
CONTACT
DOOR
1
F133
20
BR
F133
20
BR
F133
20
BR
F133
20
BR
F133
20
BR/RD
F133
20
BR/RD
F133
20
BR/RD
F133
20
BR/YL
F133
20
BR/YL
D01D
B02
12
D01P
B03
10
9
B17
LJ01J01A
4
J02A
L15
1
1
9A
PTC
3
LIFTGATE
LOCK
MOTOR
MODULE
WASHER
15
B75
C20
F133
20
BR/YL
87A
P
8
BODY
CONTROL
MODULE
85
UP-EXPORT)
(BUILT-
(8W-12-2)
(8W-61-3)
(8W-61-4)
(8W-61-7)
(8W-61-8)
(8W-10-13)
(8W-61-3)
(8W-61-7)
(8W-61-3)
(8W-61-7)
(8W-61-4)
(8W-61-8)
(8W-61-4)
(8W-61-8)
(8W-61-3)
(8W-61-7)
(8W-53-5)
(8W-45-7)
(8W-10-13)
GS001215 J988W-3
JUNCTION
BLOCK
10A
10
FUSE PTC
7
9A
RUN-ACC A31
9A
9
PTC PTC
8
9A
C2
16 3
C2
F1
20
DB
POWER
DISTRIBUTION
CENTER
9 C2
CIGAR/
ACCESSORY
RELAY
86
F1
20
DB
F1
20
DB
FRONT
WASHER
MOTOR
A
A
MOTOR
WASHER
REAR
C2
34
TN
16
F21
14
F21
16
TN
11
WINDOW
POWER
DRIVER
SWITCH
9
7
B02
D01D
F55
12
TN/DG
17
C2
TN/DG
14
F55
1
SWITCH
PASSENGER
POWER
WINDOW
D01P
B03
12
C2
13
F55
12
TN/DG
ST A41
C2
10
86
MOTOR
STARTER
ENGINE
C2 3
RELAY
7
C8
TRANSMISSION
CONTROL
MODULE
8
F45
18
YL/RD
7
C3
5
F1
20
DB
SWITCH)
FUNCTION
MULTI-
(PART OF
SWITCH
WIPER
FRONT
MODULE
WASHER
EATX MTX
2
1
T141
20
YL/RD
F45
20
YL/RD
F45
20
YL/RD
JUMPER
SWITCH
INTERLOCK
CLUTCH
2
1
SWITCH
INTERLOCK
CLUTCH
F45
20
YL/RD
T141
20
YL/RD
S
85 85
UP-EXPORT)
(BUILT-
(8W-12-2)
(8W-10-16)
(8W-10-8)
(8W-41-3)
(8W-53-3)
(8W-53-4)
(8W-60-2)
(8W-60-3)
(8W-10-16)
(8W-21-2)
(8W-21-3)
(8W-31-5)
(8W-53-2)
(8W-53-5)
J988W-3 GS001216
BATT L9
BLOCK
JUNCTION
FLASHER/
COMBINATION
DRL
1
MODULE
9 7 8
C3
26 4
C3
22
C3
L91
22
DB/PK LB/WT
22
L305
LB/YL
22
L302
G9
20
GY/BK
C2
1
10
8
C3
GY/BK
20
G9
9
C3
GY/BK
20
G9 G9
20
GY/BK
BRAKE
PRESSURE
TO
SWITCH SWITCH
TO
BRAKE
PARK IGNITION
SWITCH
TO
TO
CENTER
MESSAGE
MODULE
BODY
CONTROL
18
C2 4
C2
4
POWER
DISTRIBUTION
CENTER
X4
20
GY/OR
85
RELAY
HORN
HORN
RELAY
CONTROL
5 P50
L91
20
DB/PK
NOT
USED
C2
8
EATX MTX
TURN
SIGNAL/
HAZARD
SWITCH
(PART OF
MULTI-FUNCTION
SWITCH)
TO
86
(8W-10-29)
(8W-12-2)
(8W-46-3)
(8W-52-2)
(8W-46-3)
(8W-10-14)
(8W-46-3)
(8W-45-3)
(8W-10-10)
(8W-41-2)
(8W-52-2)
(8W-46-3)
GS001217 J988W-3
(8W-52-3)
BLOCK
JUNCTION
FLASHER/
COMBINATION
DRL
12
MODULE
3 2
C2
5 11
C2
L60
18
TN
LG
18
L61
L63
18
DG/RD
C2
28 14
C3
BR/RD
18
L62
36
C2
BR/RD
18
L62
TO
CENTER
MESSAGE
33 C3
4 5
C3
21
DG/RD
18
L63
MODULE
BODY
CONTROL
RIGHT
FRONT
PARK/
TURN
SIGNAL
LAMP
TO
TO
LAMP
SIGNAL
TURN
PARK/
FRONT
LEFT
L93
22
PK
DIMMER
HEADLAMP
FROM
SWITCH
LEFT
REAR
LAMP
ASSEMBLY
TO TO
ASSEMBLY
LAMP
REAR
RIGHT
RIGHT
REAR
LAMP
ASSEMBLY
TO TO
ASSEMBLY
LAMP
REAR
LEFT
TO
RELAY
COMBINATION
LEFT LEFT
STOP/
TURN
RELAY
TO
RIGHT
COMBINATION
RELAY
TO TO
RELAY
TURN
STOP/
RIGHT
L63
18
DG/RD
L63
18
DG/RD
L62
18
BR/RD
L62
18
BR/RD
L63 18 DG/RD
L63
18
DG/RD
L63
18
DG/RD
L62 18 BR/RD
L62 18 BR/RD
1
B99
T05
T08
B98
1
TRAILER TOW OTHERS
21 19 15
SIGNAL SIGNAL
RIGHT
REPEATER
LAMP
(BUILT-UP
-EXPORT)
TO
L62
18
BR/RD
TO
-EXPORT)
(BUILT-UP
LAMP
REPEATER
LEFT
L63
18
DG/RD
(8W-12-2)
(8W-50-2)
(8W-50-12)
(8W-51-3)
(8W-46-5)
(8W-45-5)
(8W-50-11)
(8W-50-11)
(8W-50-2)
(8W-51-4)
(8W-51-5)
(8W-51-4)
(8W-51-5)
(8W-51-4)
(8W-51-5)
(8W-51-4)
(8W-51-5)
(8W-54-2)
(8W-54-2)
(8W-54-2)
(8W-54-2)
(8W-51-3)
(8W-51-3)
J988W-3 GS001218
HEADLAMP
SWITCH
C1 6 2 C2
C4
29 21
C4
C2
14 10
C2
36 C4
BK
20
Z1
1
HALO
KEY-IN
LAMP
C4 35
SWITCH
POWER
MIRROR
SWITCH
TRACTION
CONTROL
BK
20
Z1
BK
20
Z1
1
11
28 C4
C2
SWITCH
13
CLUSTER
INSTRUMENT
2
IGNITION
Z1
20
BK
Z1
20
BK BK
18
Z1
BK
20
Z1
RECEIVER
ASH
LAMP
1
MESSAGE
CENTER
3
C4 22
BK
14
Z1
C2
2
SPEAKER
BRAND
NAME
RELAY
85
MODULE
11
COMBINATION
FLASHER/
DRL
MODULE
CONTROL
BODY
3
RELAY
UNLOCK
87A
DOOR
DRIVER
DOOR
UNLOCK
RELAY
87A
87A
RELAY
LOCK
DOOR
JUNCTION
BLOCK
8
(RKE)
Z1
18
BK
Z1
20
BK
Z2
20
BK/LG
Z2
20
BK/LG
*3
*4
FROM
SWITCH
LAMP
STOP
Z1
20
BK
2
-EXPORT)
(BUILT-UP
SWITCH
MIRROR
FOLDING
POWER
Z1
20
BK
* RHD
(RHD)
(GAS)
30
30
30
86
G300
4
87 87
87
(8W-50-9)
(8W-50-10)
(8W-50-13)
(8W-44-3)
(8W-62-2)
(8W-62-4)
(8W-62-5)
(8W-35-2)
(8W-10-14)
(8W-40-4)
(8W-44-7)
(8W-46-4)
(8W-47-4)
(8W-45-2) (8W-61-3)
(8W-61-4)
(8W-61-7)
(8W-61-8)
(8W-61-3)
(8W-61-4)
(8W-61-7)
(8W-61-8)
(8W-12-2)
(8W-61-7)
(8W-61-8)
(8W-33-3)
(8W-62-8)
(8W-15-6)
GS001219 J988W-3
BATT M1
JUNCTION
BLOCK
C4
6 13
C4
17
C4
9
MODULE
BODY
CONTROL
REMOTE
KEYLESS
ENTRY
MODULE
3
M1
20
PK
12
CENTER
MESSAGE
PK
20
M1
C3
2
C3 1
3
0
2
1 4
SWITCH
IGNITION
M1
20
PK
A81
20
DG/RD
INSTRUMENT
CLUSTER
2
M1
20
PK
C1
RADIO
7
M1
20
PK
M1
20
PK
16
DATA LINK
CONNECTOR
BLOCK
JUNCTION
10A
FUSE
2
C4 15
D1
D3
1 START
2 RUN
3 LOCK
0 OFF
4 ACC
*8
* RHD
7 P50
NOT
USED
M1
22
PK
(8W-10-11)
(8W-12-2)
(8W-45-2)
(8W-61-5)
(8W-46-2)
(8W-40-2)
(8W-47-2)
(8W-30-3)
(8W-12-2)
(8W-12-9)
(8W-10-14)
(8W-10-16)
J988W-3 GS001220
(8W-30-30)
BATT F41
JUNCTION
BLOCK
C2
19 16
C3
20
C3
POWER
MIRROR
9
F41
20
PK/VT
SWITCH LAMP
PK/VT
20
F41
1
BOX
GLOVE
PK/VT
20
F41
OVERHEAD
CONSOLE OTHERS
C20
B75
2
F41
20
PK/VT PK/VT
20
F41
TO
CS02
FRONT
READING
LAMPS/
SWITCH
TO
A
(8W-12-22)
TO
COURTESY
LAMP
RELAY
1
-EXPORT)
(BUILT-UP
MODULE
IMMOBILIZER
KEY
SENTRY
F41
20
PK/VT
(8W-10-20)
(8W-12-2)
(8W-62-2)
(8W-62-4)
(8W-44-2)
(8W-10-20)
(8W-44-2)
(8W-39-5)
GS001221 J988W-3
TO
SWITCH
HEADLAMP
TO
CS1
4
B75
C20
D4
MODULE
BODY
CONTROL
M111
22
BR/WT
86 30
87
RELAY
LAMP
COURTESY
BLOCK
JUNCTION
85
34
C3 C3
28
LB/PK
20
M113
17
C3
10
BR/LG
22
M112 M113
20
LB/PK
22
C2
M113
20
LB/PK
29
C3 C2
29 6
C2
LAMP
2
HALO
KEY-IN
PK/LB
20
M11
PK/LB
20
M11
3
B17
LJ01
M11
20
PK/LB
L15
J02A
3
PK/LB
20
M11
1
FLOOD
LAMP
LIFTGATE
LEFT
M11
20
PK/LB
RIGHT
LIFTGATE
LAMP
FLOOD
1
1
COURTESY
LAMP
DOOR
PASSENGER
DRIVER
DOOR
LAMP
COURTESY
1
M11
20
PK/LB
M11
20
PK/LB
D02
B01
3 6
B03
D01P
PK/LB
20
M11
M11
20
PK/LB
A
(8W-12-21)
FROM
JUNCTION
BLOCK
CS01
TO
DOME
LAMP OTHER
(8W-50-9)
(8W-50-10)
(8W-44-4)
(8W-45-4)
(8W-12-2)
(8W-44-3)
(8W-44-4) (8W-44-4)
(8W-44-3)
(8W-44-3)
(8W-44-4)
J988W-3 GS001222
BLOCK
JUNCTION
21 C2
MODULE
BODY
CONTROL
V10
20
BR
20
C3 18
WASHER
FRONT
TO
MOTOR
BR
20
V10
TO
SWITCH
WIPER
FRONT
2
30
C4
8
C4
23
C4
1
C4
1
C1
E2
20
OR OR
20
E2
OR
20
E2
OR
20
E2
OR
20
E2 E2
20
OR OR
18
E2 E2
20
OR
TO
SWITCH
CONTROL
TRACTION
HEATER
CONTROL
TO
INSTRUMENT
CLUSTER
TO
TO
SWITCH
HEADLAMP
ASH
RECEIVER
LAMP
TO TO
SWITCH
MIRROR
POWER
RADIO
TO
SWITCH
CONTROL
REAR
BLOWER
REAR
TO
DRIVER
DOOR
LOCK
SWITCH
TO
8 C1
E2
20
OR
E2
20
OR
TO
SWITCH
LOCK
DOOR
PASSENGER
PASSENGER
POWER
WINDOW
SWITCH
TO TO
SWITCH
WINDOW
POWER
DRIVER
E2
20
OR
E2
20
OR
E2
20
OR
4
D01D
B02
11
D01P
B03
OR
20
E2
A/C UNIVERSAL
GARAGE
DOOR
OPENER
TO
E2
20
OR
TO
FRONT
BLOWER
REAR
CONTROL
SWITCH
E2
20
OR
PANEL
LAMPS
DRIVER
READING
HEADER
FRONT
(PART OF
LAMPS)
SWITCH)
FUNCTION
MULTI-
(PART OF
31
WASHER
MODULE
(BUILT-UP
-EXPORT)
17
B75
C20
(GAS)
E2
20
OR
FRONT
CIGAR
LIGHTER/
POWER
OUTLET
TO
(8W-12-2)
(8W-45-4)
(8W-53-3)
(8W-53-3)
(8W-35-2)
(8W-42-3)
(8W-40-4)
(8W-50-9)
(8W-50-10)
(8W-44-7) (8W-62-2)
(8W-47-2)
(8W-42-6)
(8W-61-2) (8W-61-2)
(8W-61-6)
(8W-60-3) (8W-60-2)
(8W-42-6)
(8W-49-3)
(8W-53-5)
(8W-41-3)
GS001223 J988W-3
(8W-61-6)
(8W-62-4)
BLOCK
JUNCTION
22
FUSE
40A
BATT A0
CENTER
DISTRIBUTION
POWER
30
87
PARK
LAMP
RELAY
4
C1
2 C1
L7
12
BK/YL
RUN-ACC A31 BATT A4
9A
PTC
7 3
PTC
9A 15A
FUSE
5
LOGIC
20
BODY
CONTROL
MODULE
18
C3
21
C2
34
C1
11
V10
20
BR
BR
20
V10
MOTOR
WASHER
FRONT
B B
V53
18
RD/YL
WASHER
HEADLAMP
WASHER
MODULE
SWITCH)
FUNCTION
MULTI-
(PART OF
SWITCH
WIPER
FRONT
S 56 P
31 30
(8W-12-2)
(8W-10-17)
(8W-10-8)
(8W-10-8)
(8W-50-11)
(8W-10-16) (8W-10-12)
(8W-12-16) (8W-12-15) (8W-12-8)
(8W-45-4)
(8W-53-3)
(8W-53-5)
(8W-53-3)
8W - 12 - 24 8W-12 JUNCTION BLOCK
BUILT-UP-EXPORT
NS/GS
J988W-3 GS001224
6
FUSE
20A
BATT A0
CENTER
DISTRIBUTION
POWER
30
87
LOW
BEAM
RELAY
8
C5
L43
18
VT
BLOCK
JUNCTION
16 C1
A
LEFT
LOW
HEADLAMP
L43
18
VT
85 87
30 86
12
C1
10
L94
20
OR/WT
B20 B23
P18 20
L94
20
OR/WT
SWITCH)
FUNCTION
MULTI-
(PART OF
SWITCH
DIMMER
HEADLAMP
C1
31
L39
18
LB
LEFT
FOG
LAMP
LAMP
FOG
RIGHT
L39
18
LB
1
1
C1
25
L39
18
LB
B3 B23
P18 3
L39
18
LB
C2 5
SWITCH
HEADLAMP
FOG
LAMP
RELAY
(8W-10-33)
(8W-10-8)
(8W-10-10)
(8W-50-2)
(8W-12-2)
(8W-50-5)
(8W-50-5)
(8W-50-5)
(8W-50-5)
(8W-50-9)
(8W-50-5)
NS/GS 8W-12 JUNCTION BLOCK
EXCEPT BUILT-UP-EXPORT/CHRYSLER
8W - 12 - 25
GS001225 J988W-3
BATT A0
G300
8
Z1
14
BK
JUNCTION
BLOCK
2
18
FUSE
15A
POWER
DISTRIBUTION
CENTER
C2
30
C2
15 C2
F41
20
PK/VT
85 30
87 86
MIRROR
FOLD
RELAY RELAY
UNFOLD
MIRROR
87A 87 86 87A
30 85
C1
36
C2
2
YL/RD
20
P174
C1 74
MODULE
CONTROL
BODY
P171
20
VT/WT
71 C1
6 C2
5
C2
DRIVER
POWER
MIRROR MIRROR
POWER
PASSENGER
C2
5
C2 6
P159
20
DG
P159
20
DG
P160
20
LB
P160
20
LB
11
C3 C4
11
POWER
FOLDING
MIRROR
SWITCH
2
1
P136
20
YL
SWITCH
MIRROR
FOLDING
39 C2
SIGNAL
36
C4
BK
20
Z1
HALO
KEY-IN
FROM
LAMP
Z1
20
BK
POWER POWER
1 2
M M
1 UNFOLD
2 FOLD
RELAY
FOLD
MIRROR
POWER
RELAY
UNFOLD
MIRROR
POWER POWER
(8W-10-8)
(8W-15-6)
(8W-12-2)
(8W-10-20)
(8W-10-9)
(8W-45-10)
(8W-44-3)
(8W-62-8) (8W-62-8)
(8W-62-8) (8W-62-8)
(8W-62-8)
(8W-12-19)
8W - 12 - 26 8W-12 JUNCTION BLOCK
BUILT-UP-EXPORT
NS/GS
J988W-3 GS001226
8W-15 GROUND DISTRIBUTION
Component Page
A/C Compressor Cl utch . . . . . . . . . . . . . . . . . . . .8W-15-2, 3
A/C Heater Control . . . . . . . . . . . . . . . . . . . . . . . .8W-15-4
Ai rbag Control Modul e . . . . . . . . . . . . . . . . . . . . . .8W-15-4
Al l Wheel Dri ve Sol enoi d . . . . . . . . . . . . . . . . . . . .8W-15-13
Ash Recei ver Lamp . . . . . . . . . . . . . . . . . . . . . . . .8W-15-6
Automati c Day/Ni ght Mi rror . . . . . . . . . . . . . . . . . . .8W-15-5
AW4 B13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-13
AWS1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-13
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-2, 3
Body Control Modul e . . . . . . . . . . . . . . . . . . . . . . .8W-15-6
Brake Pressure Swi tch . . . . . . . . . . . . . . . . . . . . . .8W-15-8
BS08 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-5
BS31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-3
BS40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-3
BS41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-3
Center Hi gh Mounted Stop Lamp . . . . . . . . . . . . . . .8W-15-14
Ci gar/Accessory Rel ay . . . . . . . . . . . . . . . . . . . . . . .8W-15-7
Cl ockspri ng . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-4
Cl utch Swi tch . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-8
Combi nati on Fl asher/DRL Modul e . . . . . . . . . . . . . . .8W-15-6
Control l er Anti -Lock Brake. . . . . . . . . . . . . . . . . . . .8W-15-4
Crank Case Heater . . . . . . . . . . . . . . . . . . . . . . . .8W-15-3
CS06 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-11, 12
Data Li nk Connector . . . . . . . . . . . . . . . . . . . .8W-15-2, 4, 12
Door Lock Rel ay . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-6
Door Unl ock Rel ay . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-6
Downstream Heated Oxygen Sensor . . . . . . . . . . . . . .8W-15-5
Dri ver Door Arm/Di sarm Swi tch . . . . . . . . . . . . .8W-15-11, 12
Dri ver Door Courtesy Lamp . . . . . . . . . . . . . . . . . . .8W-15-7
Dri ver Door Lock Swi tch . . . . . . . . . . . . . . . . . .8W-15-11, 12
Dri ver Door Unl ock Rel ay . . . . . . . . . . . . . . . . . . . .8W-15-6
Dri ver Heated Seat Back . . . . . . . . . . . . . . . . . . . . .8W-15-9
Dri ver Heated Seat Cushi on . . . . . . . . . . . . . . . . . . .8W-15-9
Dri ver Heated Seat Modul e . . . . . . . . . . . . . . . . . . .8W-15-9
Dri ver Heated Seat Swi tch . . . . . . . . . . . . . . . . . . . .8W-15-9
Dri ver Power Mi rror . . . . . . . . . . . . . . . . . . . . . . . .8W-15-4
Dri ver Power Seat Swi tch . . . . . . . . . . . . . . . . . . . .8W-15-5
Dri ver Power Wi ndow Swi tch . . . . . . . . . . . . . . . . . .8W-15-7
DS01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-7
EC1 C19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-5
Engi ne Speed Sensor . . . . . . . . . . . . . . . . . . . . . . .8W-15-3
ES01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-3
ES02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-3
ES11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-2
ES12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-3
ES18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-2
ES23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-2
ES30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-3
ES31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-3
Front Bl ower Motor Rel ay . . . . . . . . . . . . . . . . . . . .8W-15-7
Front Ci gar Li ghter/Power Outl et . . . . . . . . . . . . . . .8W-15-4
Fuel Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-3
Fuel Heater Rel ay . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-3
Fuel Tank Modul e . . . . . . . . . . . . . . . . . . . . . . . .8W-15-13
G100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-2, 3
G101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-2
G102 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-2, 3
G103 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-2, 3
G104 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-4
G200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-4
G201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-4
G202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-5
G204 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-4
G300 . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-5, 6, 7, 8, 9
G301 . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-10, 11, 12
G302. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-13
G400. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-14
Headl amp Di mmer Swi tch . . . . . . . . . . . . . . . . . . . .8W-15-4
Headl amp Swi tch . . . . . . . . . . . . . . . . . . . . . . . .8W-15-4, 6
Headl amp Washer . . . . . . . . . . . . . . . . . . . . . . . .8W-15-10
Hi gh Note Horn . . . . . . . . . . . . . . . . . . . . . . .8W-15-11, 12
Hood Ajar Swi tch . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-10
HS1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-9
HS3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-9
HS5D B09 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-9
HS5P B56 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-9
I gni ti on Swi tch . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-4, 6
I nstrument Cl uster . . . . . . . . . . . . . . . . . . . . . . .8W-15-4, 6
Juncti on Bl ock . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-6
Key-I n Hal o Lamp . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-6
Left Combi nati on Rel ay . . . . . . . . . . . . . . . . . . . . .8W-15-13
Component Page
Left Door Speaker . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-5
Left Front Park/Turn Si gnal Lamp . . . . . . . . . . . . . . .8W-15-7
Left Headl amp . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-8
Left Headl amp Level i ng Motor . . . . . . . . . . . . . . . . .8W-15-8
Left Hi gh Headl amp . . . . . . . . . . . . . . . . . . . . . . . .8W-15-8
Left Li ftgate Fl ood Lamp . . . . . . . . . . . . . . . . . . . .8W-15-14
Left Low Headl amp . . . . . . . . . . . . . . . . . . . . . . . .8W-15-8
Left Rear Door Ajar Swi tch . . . . . . . . . . . . . . . . . . .8W-15-13
Left Rear Lamp Assembl y. . . . . . . . . . . . . . . . . . . .8W-15-13
Left Rear Speaker . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-5
Left Repeater Lamp . . . . . . . . . . . . . . . . . . . . . . . .8W-15-5
Left Speed Control Swi tch . . . . . . . . . . . . . . . . . . . .8W-15-4
Left Stop/Turn Si gnal Rel ay . . . . . . . . . . . . . . . . . .8W-15-13
Li cense Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-14
Li ftgate Ajar Swi tch . . . . . . . . . . . . . . . . . . . . . . .8W-15-14
Li ftgate Arm/Di sarm Swi tch . . . . . . . . . . . . . . . . . .8W-15-14
Low Cool ant Level Swi tch . . . . . . . . . . . . . . . . . . . .8W-15-3
Low Note Horn . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-10
Low Washer Fl ui d Swi tch . . . . . . . . . . . . . . . . .8W-15-11, 12
Memory Power Seat Swi tch . . . . . . . . . . . . . . . . . .8W-15-5, 9
Memory Seat/Mi rror Modul e . . . . . . . . . . . . . . . . .8W-15-5, 9
Memory Set Swi tch . . . . . . . . . . . . . . . . . . . . . . . .8W-15-7
Message Center . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-6
Name Brand Speaker Rel ay . . . . . . . . . . . . . . . . . . .8W-15-6
Needl e Movement Sensor . . . . . . . . . . . . . . . . . . . . .8W-15-3
Overhead Consol e . . . . . . . . . . . . . . . . . . . . . .8W-15-11, 12
Passenger Door Arm/Di sarm Swi tch . . . . . . . . . . . . .8W-15-10
Passenger Door Courtesy Lamp . . . . . . . . . . . . . . . . .8W-15-7
Passenger Door Lock Swi tch . . . . . . . . . . . . . . . . . .8W-15-10
Passenger Heated Seat Back. . . . . . . . . . . . . . . . . . .8W-15-9
Passenger Heated Seat Cushi on. . . . . . . . . . . . . . . . .8W-15-9
Passenger Heated Seat Modul e . . . . . . . . . . . . . . . . .8W-15-9
Passenger Heated Seat Swi tch . . . . . . . . . . . . . . . . .8W-15-9
Passenger Power Mi rror . . . . . . . . . . . . . . . . . . . . .8W-15-4
Passenger Power Seat Swi tch . . . . . . . . . . . . . . . .8W-15-5, 12
Passenger Power Wi ndow Swi tch . . . . . . . . . . . . . . . .8W-15-7
Power Di stri buti on Center . . . . . . . . . . . . . . . . .8W-15-2, 3, 7
Power Fol di ng Mi rror Swi tch . . . . . . . . . . . . . . . . . .8W-15-6
Power Mi rror Swi tch . . . . . . . . . . . . . . . . . . . . . . .8W-15-6
Powertrai n Control Modul e . . . . . . . . . . . . . . . . . .8W-15-2, 3
Radi ator Fan Di sconnect . . . . . . . . . . . . . . . . . . . . .8W-15-3
Radi ator Fan No. 1 . . . . . . . . . . . . . . . . . . . . . . . .8W-15-2
Radi ator Fan No. 2 . . . . . . . . . . . . . . . . . . . . . . . .8W-15-2
Radi ator Fan Rel ay . . . . . . . . . . . . . . . . . . . . . . . .8W-15-2
Radi ator Fan Rel ay No. 1. . . . . . . . . . . . . . . . . . . . .8W-15-3
Radi o . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-5
Rear Bl ower Front Control Swi tch . . . . . . . . . . . . . . .8W-15-4
Rear Bl ower Rear Control Swi tch . . . . . . . . . . . . . . .8W-15-13
Rear Ci gar Li ghter/Power Outl et . . . . . . . . . . . . . . .8W-15-13
Rear Wi ndow Defogger . . . . . . . . . . . . . . . . . . . . .8W-15-14
Rear Wi per Motor . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-14
Remote Keyl ess Entry Modul e. . . . . . . . . . . . . . . . . .8W-15-4
RF3 E40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-2
RFS2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-2
Ri ght Combi nati on Rel ay . . . . . . . . . . . . . . . . . . . .8W-15-13
Ri ght Door Speaker . . . . . . . . . . . . . . . . . . . . . . . .8W-15-5
Ri ght Front Park/Turn Si gnal Lamp . . . . . . . . . . . . .8W-15-10
Ri ght Headl amp. . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-10
Ri ght Headl amp Level i ng Motor . . . . . . . . . . . . . . . .8W-15-10
Ri ght Hi gh Headl amp . . . . . . . . . . . . . . . . . . . . . .8W-15-10
Ri ght Li ftgate Fl ood Lamp . . . . . . . . . . . . . . . . . . .8W-15-14
Ri ght Low Headl amp . . . . . . . . . . . . . . . . . . . . . .8W-15-10
Ri ght Rear Door Ajar Swi tch . . . . . . . . . . . . . . . . . .8W-15-13
Ri ght Rear Lamp Assembl y . . . . . . . . . . . . . . . . . . .8W-15-13
Ri ght Rear Speaker . . . . . . . . . . . . . . . . . . . . . . . .8W-15-5
Ri ght Repeater Lamp . . . . . . . . . . . . . . . . . . . . . .8W-15-10
Ri ght Speed Control Swi tch . . . . . . . . . . . . . . . . . . .8W-15-4
Ri ght Stop/Turn Si gnal Rel ay . . . . . . . . . . . . . . . . .8W-15-13
Seat Bel t Swi tch . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-8
Sentry Key I mmobi l i zer Modul e. . . . . . . . . . . . . . . . .8W-15-4
Stop Lamp Swi tch . . . . . . . . . . . . . . . . . . . . . . .8W-15-6, 7
Tracti on Control Swi tch . . . . . . . . . . . . . . . . . . . . . .8W-15-6
Trai l er Tow Connector . . . . . . . . . . . . . . . . . . . . . .8W-15-13
Transmi ssi on Control Modul e . . . . . . . . . . . . . . . . . .8W-15-2
Transmi ssi on Control Rel ay . . . . . . . . . . . . . . . . . . .8W-15-2
Uni versal Garage Door Opener . . . . . . . . . . . . . .8W-15-11, 12
Upstream Heated Oxygen Sensor . . . . . . . . . . . . . . . .8W-15-2
Vehi cl e Speed Control Servo . . . . . . . . . . . . . . . . . . .8W-15-2
Wi per Modul e . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-5
Wi per On Rel ay. . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-7
NS/GS 8W - 15 GROUND DISTRIBUTION 8W - 15 - 1
BATTERY
Z0
6
BK
G103 G100
Z0
8
BK
Z0
10
BK
MODULE
CONTROL
TRANSMISSION
53 57
BK/YL
16
Z14 Z13
16
BK/RD
ES11
Z12
18
BK/TN
50 10
POWERTRAIN
CONTROL
MODULE
C1 C2
BK/TN
18
Z12
Z11
20
BK/WT
5
CONNECTOR
DATA LINK
Z11
20
BK/WT
Z11
18
BK/WT
24 P34
B23
9
B70
E43
G102
BK
12
Z1
ES23
RFS2
NO. 2
FAN
RADIATOR
2 2
RADIATOR
FAN
NO. 1
Z1
12
BK
Z1
12
BK
Z1
12
BK
E40
RF3
2
Z1
12
BK
RELAY
FAN
RADIATOR
1
Z1
18
BK BK
14
Z1
2
A/C
COMPRESSOR
CLUTCH
CONTROL
SPEED
VEHICLE
4
Z1
18
BK BK
18
Z1
Z1
10
BK
G101
SERVO
ES18
SENSOR
UPSTREAM
HEATED
OXYGEN
A24
1
85
TRANSMISSION
CONTROL
RELAY
CENTER
DISTRIBUTION
POWER
4
C8
Z16
18
BK
86
(8W-20-2)
(8W-31-2) (8W-30-2)
(8W-30-3)
(8W-42-8) (8W-42-8)
(8W-42-8) (8W-42-7)
(8W-33-3) (8W-30-7)
(8W-30-21)
(8W-31-2)
(8W-10-9)
8W - 15 - 2 8W-15 GROUND DISTRIBUTION
GAS
NS/GS
J988W-3 GS001502
BATTERY
Z0
2
BK
G103 G100
Z0
6
BK
Z0
10
BK
ES01
Z12
16
BK/TN
24 1
POWERTRAIN
CONTROL
MODULE
BK/TN
16
Z12
Z12
14
BK/TN
Z1
16
BK
3
B107
E95
Z12
16
BK/TN
46
BS31
BK
16
Z1
ES02
2
FUEL
HEATER
Z1
18
BK
2
BK
18
Z1
SWITCH
2
LOW
COOLANT
LEVEL
Z1
20
BK
CENTER
DISTRIBUTION
POWER
3
C6
Z1
20
BK
RELAY
HEATER
FUEL
85
SENSOR
MOVEMENT
NEEDLE
BK
18
Z122
ES31
2
E97
B106
Z122
18
BK
Z1
18
BK
BS41
Z1
18
BK
ENGINE
SPEED
SENSOR
Z122
18
BK
ES30
BK
18
Z1
BK
18
Z122
7
Z12
18
BK
BS40
BK
18
Z1
Z12
14
BK/TN
A
(8W-15-5)
TO
G300
B
(8W-15-12)
TO
G301
RELAY
RADIATOR
2
NO. 1
FAN FAN
1
RADIATOR
DISCONNECT
Z1
12
BK BK
12
Z1
ES12
Z1
12
BK
G102
SHIELD SHIELD
Z1
18
BK
2
A/C
COMPRESSOR
CLUTCH
CRANK
CASE
HEATER
86
(8W-20-3)
(8W-30-28)
(8W-30-29)
(8W-45-9)
(8W-10-9)
(8W-30-29)
(8W-30-35) (8W-30-35)
(8W-42-10)
(8W-42-10)
(8W-42-9)
(8W-30-29)
NS/GS 8W-15 GROUND DISTRIBUTION
DIESEL
8W - 15 - 3
GS001503 J988W-3
BRAKE
ANTI-LOCK
CONTROLLER
BK
12
Z7
G104
Z2
20
BK/LG
4
CONNECTOR
DATA LINK
8 24
Z7
12
BK
G200
4
MODULE
ENTRY
KEYLESS
REMOTE
5
MIRROR
POWER
PASSENGER
3
7
CLUSTER
INSTRUMENT
IGNITION
SWITCH
C1
1
21
C1
CONTROL
CLOCKSPRING
Z2
20
BK/LG
Z2
20
BK
BK
20
Z1 Z1
20
BK
HEADLAMP
DIMMER
8
Z1
18
BK
BK
16
Z1
BK/LG
20
Z2 Z2
18
BK/LG
BK
20
Z1
C2
6
A/C
CONTROL
BK
12
Z1
Z1
12
BK
FRONT
BLOWER
REAR
7
SWITCH
CONTROL
G201
12 3 14 7 6 13 10 2 5 1
Z2
20
BK
Z2
22
BK
SWITCH
CONTROL
SPEED
LEFT RIGHT
SPEED
CONTROL
SWITCH
SWITCH
C1
5
MIRROR
POWER
DRIVER
HEATER
A/C
HEATER
MULTI-
FUNCTION
SWITCH)
(PART OF
C1
OUTLET
POWER
LIGHTER/
CIGAR
FRONT
8
Z1
18
BK
8
P50
NOT
USED
11
Z2
20
BK/LG
2
-EXPORT)
(BUILT-UP
MODULE
IMMOBILIZER
KEY
SENTRY
1
BK
20
Z1
9
-EXPORT)
(BUILT-UP
SWITCH
HEADLAMP
3 C2
C2
11
AIRBAG
CONTROL
MODULE
G204
Z2
18
BK/LG
C1
(8W-35-2)
(8W-30-3)
(8W-30-30)
(8W-61-5)
(8W-48-2)
(8W-50-2)
(8W-40-2)
(8W-10-14)
(8W-42-3)
(8W-42-2)
(8W-42-6)
(8W-33-2)
(8W-33-4)
(8W-33-2)
(8W-33-4)
(8W-48-2)
(8W-41-3)
(8W-39-5)
(8W-50-8)
(8W-43-2)
8W - 15 - 4 8W-15 GROUND DISTRIBUTION NS/GS
J988W-3 GS001504
2
LEFT
DOOR
SPEAKER
BK/DG
16
X15
SPEAKER
DOOR
RIGHT
2
X15
16
BK/DG
1
D02
B01
1
D01P
B03
X15
16
BK/DG
X15
16
BK/DG
X15
16
BK/DG
SPEAKER
REAR
LEFT
2 2
RIGHT
REAR
SPEAKER
BK/DG
16
X15
BS08
P34
B23 A11
X15
16
BK/DG
RADIO
G202
14
G300
2
4
MODULE
WIPER
PASSENGER
POWER
SEAT
SWITCH
1
DOWNSTREAM
HEATED
OXYGEN
SENSOR
1
7
MODULE
MIRROR
SEAT/
MEMORY
C2
MEMORY
POWER
SEAT
SWITCH
1
Z1
20
BK
C19
EC1
2
12
C20
B75
Z1
20
BK
Z1
20
BK
12 7 3 2
BK
14
Z1
BK
12
Z1
1
S02
B56
Z12
20
BK/TN
B09
S02
1
Z1
12
BK
(PREMIUM) (PREMIUM)
11
1
SWITCH
SEAT
POWER
DRIVER
BK/DG
16
X15
Z1
14
BK
AUTOMATIC
DAY/NIGHT
MIRROR
2
-EXPORT)
(BUILT-UP
LAMP
REPEATER
LEFT
Z1
18
BK
A
(8W-15-3)
BS31
(DIESEL)
FROM
Z12
14
BK/TN
MEMORY OTHER
Z1
14
BK
Z1
14
BK
Z1
20
BK
(8W-47-2)
(8W-53-2)
(8W-63-3)
(8W-30-7)
(8W-30-21)
(8W-62-3)
(8W-63-4)
(8W-63-5)
(8W-47-6)
(8W-47-7)
(8W-47-6)
(8W-47-7)
(8W-47-5) (8W-47-5)
(8W-63-2)
(8W-44-6)
(8W-52-2)
NS/GS 8W-15 GROUND DISTRIBUTION 8W - 15 - 5
GS001505 J988W-3
HEADLAMP
SWITCH
C1 6 2 C2
C4
29 21
C4
C2
14 10
C2
36 C4
BK
20
Z1
1
HALO
KEY-IN
LAMP
C4 35
SWITCH
POWER
MIRROR
SWITCH
TRACTION
CONTROL
BK
20
Z1
BK
20
Z1
1
11
28 C4
C2
SWITCH
13
CLUSTER
INSTRUMENT
2
IGNITION
Z1
20
BK
Z1
20
BK BK
18
Z1
BK
20
Z1
RECEIVER
ASH
LAMP
1
MESSAGE
CENTER
3
C4 22
BK
14
Z1
C2
2
SPEAKER
BRAND
NAME
RELAY
85
MODULE
11
COMBINATION
FLASHER/
DRL
MODULE
CONTROL
BODY
3
RELAY
UNLOCK
87A
DOOR
DRIVER
DOOR
UNLOCK
RELAY
87A
87A
RELAY
LOCK
DOOR
JUNCTION
BLOCK
8
G300
(RKE)
Z1
18
BK
Z1
20
BK
Z2
20
BK/LG
Z2
20
BK/LG
*3
*4
FROM
SWITCH
LAMP
STOP
Z1
20
BK
2
-EXPORT)
(BUILT-UP
SWITCH
MIRROR
FOLDING
POWER
Z1
20
BK
* RHD
(RHD)
(GAS)
30 30
30 86
87
87 87
4
(8W-50-9)
(8W-50-10)
(8W-50-13)
(8W-44-3)
(8W-62-2)
(8W-62-4)
(8W-62-5)
(8W-35-2)
(8W-10-14)
(8W-40-4)
(8W-44-7)
(8W-46-4)
(8W-47-4)
(8W-45-2) (8W-61-3)
(8W-61-4)
(8W-61-7)
(8W-61-8)
(8W-61-3)
(8W-61-4)
(8W-61-7)
(8W-61-8)
(8W-12-2)
(8W-61-7)
(8W-61-8)
(8W-33-3)
(8W-62-8)
J988W-3 GS001506
WIPER
ON
RELAY
6
G300
11 10 5
5
D01P
B03
BK
18
Z1
BK
20
Z1
BK
20
Z1
BK
18
Z1
BK
20
Z1
B02
D01D
10
BK
12
Z1
BK
12
Z1
DS01
Z1
20
BK
Z1
20
BK BK
12
Z1
RELAY
85
FRONT
BLOWER
MOTOR
13
SWITCH
WINDOW
POWER
DRIVER DRIVER
DOOR
COURTESY
LAMP
2
SWITCH
MEMORY
SET
3
2
LAMP
COURTESY
DOOR
PASSENGER PASSENGER
POWER
WINDOW
SWITCH
7
SIGNAL
LAMP
LEFT
FRONT
PARK/
TURN
3
RELAY
ACCESSORY
CIGAR/
85
2
C4
CENTER
DISTRIBUTION
POWER
Z1
18
BK
87A
FROM
SWITCH
LAMP
STOP
*2
* BUILT-UP-EXPORT
86 86
30
87
(LHD)
(8W-53-2)
(8W-53-3)
(8W-42-2)
(8W-60-2)
(8W-60-3)
(8W-44-3)
(8W-62-3)
(8W-63-4)
(8W-44-3) (8W-60-3)
(8W-50-11)
(8W-50-12)
(8W-41-3)
(8W-10-8)
(8W-33-3)
GS001507 J988W-3
(8W-33-5)
G300
1
BUILT-UP-EXPORT EXCEPT BUILT-
UP-EXPORT
B
(CHRYSLER)
HEADLAMP
HIGH
LEFT
2
SEAT
BELT
SWITCH
SWITCH
CLUTCH
2
LEFT
HEADLAMP
LEVELING
MOTOR
1
Z1
20
BK
Z1
20
BK
Z1
20
BK
Z1
20
BK
UP-EXPORT
EXCEPT BUILT- BUILT-UP
-EXPORT
9
B
BRAKE
PRESSURE
SWITCH
Z1
20
BK
Z1
20
BK
Z1
20
BK
Z1
20
BK
3
LEFT
HEADLAMP
OTHER CHRYSLER
B
LEFT
LOW
HEADLAMP
HEADLAMP
LEFT
2
Z1
20
BK
Z1
20
BK
(DIESEL)
(8W-50-5)
(8W-40-4) (8W-30-39)
(8W-50-8)
(8W-46-3)
(8W-50-6)
(8W-50-5)
(8W-50-6)
J988W-3 GS001508
2
G300
7
B09
HS5D
1
Z1
14
BK
Z1
12
BK
BK
12
Z1
BK
14
Z1
1
HS5P
B56
HS1
Z1
18
BK
Z1
18
BK
Z1
18
BK
Z1
18
BK
F
MODULE
SEAT
HEATED
DRIVER
DRIVER
HEATED
SEAT
SWITCH
E
D
CUSHION
SEAT
HEATED
DRIVER
DRIVER
HEATED
SEAT
BACK
B
B
BACK
SEAT
HEATED
PASSENGER
PASSENGER
HEATED
SEAT
CUSHION
D
E
SWITCH
SEAT
HEATED
PASSENGER
PASSENGER
HEATED
SEAT
MODULE
F
BK
18
Z1
BK
18
Z1
BK
18
Z1
BK
18
Z1
HS3
7
MODULE
MIRROR
SEAT/
MEMORY
MEMORY
POWER
SEAT
SWITCH
1
1
HS6D
S02
Z1
20
BK
Z1
14
BK
Z1 14BK
C2
(8W-63-7)
(8W-63-7)
(8W-63-7)
(8W-63-7)
(8W-63-8)
(8W-63-8)
(8W-63-8)
(8W-63-8)
(8W-62-3)
(8W-63-4)
(8W-63-5)
(8W-63-5)
HEATED SEATS
8W - 15 - 9
GS001509 J988W-3
13
B
HORN
LOW
Z1
18
BK
7 2
3
D01P
B03
Z2
20
BK/LG
Z2
20
BK/LG
LOCK
PASSENGER
SWITCH
3
DOOR
ARM/
1
PASSENGER
DOOR
DISARM
Z2
20
BK/LG
NOTE
9
BK
20
Z1
LEVELING
1
MOTOR
RIGHT
HEADLAMP
2
REPEATER
RIGHT
Z1
18
BK
10
SWITCH
AJAR
HOOD
SWITCH
BK
18
Z1
12 8
2
G301
LAMP
-EXPORT)
(BUILT-UP
11
A
-EXPORT)
(BUILT-UP
WASHER
HEADLAMP
Z1
18
BK
EXCEPT BUILT
-UP-EXPORT -EXPORT
BUILT-UP
(BUILT-UP
-EXPORT)
BUILT-UP EXCEPT
-EXPORT BUILT-
RIGHT
HEADLAMP
(DODGE/
PLYMOUTH)
2
B
Z1
20
BK BK
20
Z1
B
BK
20
Z1
3
HEADLAMP
RIGHT
Z1
20
BK
(CHRYSLER)
HEADLAMP
LOW
RIGHT
RIGHT
HIGH
HEADLAMP
(CHRYSLER)
3
2
UP-
EXPORT
LAMP
SIGNAL
TURN
PARK/
FRONT
RIGHT
RIGHT
FRONT
PARK/
TURN
SIGNAL
LAMP
Z1
20
BK
Z1
18
BK
RKE OTHER
Z2
20
BK/LG
Z2
20
BK/LG
(8W-41-2)
(8W-61-2)
(8W-61-6) (8W-39-3)
(8W-44-5)
(8W-51-3)
(8W-53-5)
(8W-50-8)
(8W-50-6)
(8W-50-8)
(8W-50-4)
(8W-50-4)
(8W-50-11)
(8W-50-12)
(8W-50-11)
J988W-3 GS001510
SWITCH
HORN
NOTE
BK
18
Z1
BK/LG
20
Z2
ARM/
1
DRIVER
DOOR
DISARM
LOCK
DRIVER
SWITCH
3
DOOR
BK/LG
20
Z2
3
D01D
B02
Z2
20
BK/LG
3
BK
20
Z1
FLUID
A
SWITCH
LOW
WASHER
14
GROUND
Z2
18
BK/LG
B75
C20
9
B
HIGH
BK/LG
18
Z2 Z1
18
BK
5 1
OVERHEAD
CONSOLE
3
G301
CS06
GARAGE
UNIVERSAL
OPENER
3
DOOR
READING
LAMPS/
(PART OF
FRONT
SWITCH)
Z2
18
BK/LG
COMPASS/
MINI-TRIP
COMPUTER
RKE OTHER
Z2
20
BK/LG
Z2
20
BK/LG
(8W-39-3)
(8W-41-2)
(8W-61-2)
(8W-61-6)
(8W-53-3)
(8W-49-2)
(8W-49-3)
GAS
8W - 15 - 11
GS001511 J988W-3
A24 B23
P34 24
BK/WT
20
Z11
DATA LINK
CONNECTOR
5
BK/WT
20
Z11
BK
18
Z1
1
S02
B56
SWITCH
Z1
12
BK
BK
14
Z1
POWER
PASSENGER
SEAT
1
5
FROM
B106
B
(8W-15-3)
6
BK
18
Z12
G301
1
Z2
18
BK/LG
HIGH
B
9
C20
B75
BK/LG
18
Z2
14
WASHER
LOW
SWITCH
A
FLUID
Z1
20
BK
3
BK/LG
20
Z2
B02
D01D
3
Z2
20
BK/LG
DOOR
3
SWITCH
DRIVER
LOCK
DISARM
DOOR
DRIVER
1
ARM/
Z2
20
BK/LG
NOTE
HORN
SWITCH
DOOR
GARAGE
3
UNIVERSAL
3
CS06
OPENER
(PART OF
FRONT
READING
LAMPS/
SWITCH)
CONSOLE
OVERHEAD
Z2
18
BK/LG
Z2
18
BK/LG
RKE OTHER
Z2
20
BK/LG
Z2
20
BK/LG
(8W-30-30)
(8W-63-3)
(8W-53-3)
(8W-61-2)
(8W-61-6)
(8W-41-2)
(8W-39-3)
(8W-49-3)
(8W-49-2)
8W - 15 - 12 8W-15 GROUND DISTRIBUTION
DIESEL
NS/GS
J988W-3 GS001512
8
G302
4
3
14 12 9 11
BK
18
Z1 Z1
16
BK
3 5
AJAR
REAR
LEFT
SWITCH
1
DOOR
Z1
18
BK
Z1
18
BK
DOOR
1
SWITCH
RIGHT
REAR
AJAR
CONTROL
BLOWER
REAR
SWITCH
REAR
LIGHTER/
OUTLET
REAR
CIGAR
POWER
ASSEMBLY
REAR
LEFT
LAMP
6
6
Z1
20
BK
LAMP
RIGHT
REAR
ASSEMBLY
1
MODULE
FUEL
TANK
OTHER
10
Z1
12
BK
TO
B17
TOW
TRAILER
CONNECTOR
3
Z1
18
WT
OTHERS
ASSEMBLY
REAR
RIGHT
LAMP
6
Z1
20
BK
Z1
20
BK
Z1
20
BK
6
T08
B98
6
LAMP
LEFT
REAR
ASSEMBLY
B99
T05
6
Z1
20
BK
BK
18
Z1
TURN
LEFT
STOP/
2
SIGNAL
RELAY
COMBINATION
RIGHT
RELAY
2
TURN
RIGHT
STOP/
SIGNAL
RELAY
RELAY
LEFT
COMBINATION
2
Z1
18
BK
Z1
18
BK
Z1 18 BK
TRAILER TOW
2
AWS1
1
AW4
B13 B13
AW4
1
Z1
16
BK
Z1
16
BK
(3.8L)
SOLENOID
DRIVE
WHEEL
ALL
3.8L
Z1
14
BK
Z1
14
BK
1 C1 1 C2
Z1
16
BK
3.8L OTHERS
* BUILT-UP-EXPORT
C
(8W-15-14)
*1 *1
*1
*1
Z1
18
BK
Z1
18
BK
Z1
20
BK
(8W-44-5)
(8W-44-5)
(8W-42-6)
(8W-41-3)
(8W-51-4)
(8W-51-5)
(8W-51-4)
(8W-51-5)
(8W-30-6)
(8W-30-20)
(8W-45-9)
(8W-54-3)
(8W-51-4)
(8W-51-5)
(8W-51-4)
(8W-51-5)
(8W-54-3)
(8W-54-3)
(8W-54-3)
(8W-54-3)
(8W-31-3)
GS001513 J988W-3
FROM
G302
Z1
12
BK
Z1
12
BK
WINDOW
REAR
DEFOGGER
BK
18
Z1
1
MOTOR
REAR
WIPER
Z1
20
BK
2
FLOOD
RIGHT
LIFTGATE
LAMP
Z1
20
BK
LAMP
LIFTGATE
LEFT
FLOOD
2
Z1
20
BK
AJAR
LIFTGATE
SWITCH
1
BK
20
Z1
STOP
HIGH
CENTER
LAMP
1
MOUNTED
BK
20
Z1
1
LAMP
LICENSE
BK/LG
20
Z2
1
DISARM
LIFTGATE
ARM/
SWITCH
6 8
L15
J02A
1
LJ01
B17
11
BK
12
Z1
BK
12
Z1
1
G400
9 7 2 3 11 5
C
(8W-15-13)
(8W-48-2)
(8W-53-4)
(8W-44-4)
(8W-44-4)
(8W-44-5)
(8W-51-7)
(8W-51-2)
(8W-39-3)
J988W-3 GS001514
8W-20 CHARGING SYSTEM
Component Page
Automati c Shut Down Rel ay . . . . . . . . . . . . .8W-20-2
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-20-2, 3
BS33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-20-3
Di esel Power Rel ay . . . . . . . . . . . . . . . . . . . .8W-20-3
Engi ne Starter Motor . . . . . . . . . . . . . . . .8W-20-2, 3
ES01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-20-3
ES06 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-20-3
ES09 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-20-2
ES11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-20-2, 3
ES12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-20-2
ES26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-20-3
Component Page
ES28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-20-3
Fuse 17 (PDC). . . . . . . . . . . . . . . . . . . . . .8W-20-2, 3
Fusi bl e Li nk . . . . . . . . . . . . . . . . . . . . . . .8W-20-2, 3
G100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-20-2, 3
G103 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-20-2, 3
Generator . . . . . . . . . . . . . . . . . . . . . . . . .8W-20-2, 3
Gl ow Pl ug Rel ay . . . . . . . . . . . . . . . . . . . . . .8W-20-3
Power Di stri buti on Center . . . . . . . . . . . . .8W-20-2, 3
Powertrai n Control Modul e . . . . . . . . . . . .8W-20-2, 3
Vol tage Regul ator . . . . . . . . . . . . . . . . . . . . .8W-20-3
NS/GS 8W - 20 CHARGING SYSTEM 8W - 20 - 1
BK/GY
6
A11
G103
Z0
6
BK
A0
6
RD
87
30
20A
FUSE
17
DG
18
K20
8 C1
GENERATOR
FIELD
DRIVER
CENTER
DISTRIBUTION
POWER
BK
8
Z0
G100
BATTERY
DG/OR
18
A142
GENERATOR
1
2
C1 6
MODULE
CONTROL
POWERTRAIN
AUTOMATIC
SHUT
DOWN
RELAY
5
C6
ES12
A142
18
DG/OR
DG/OR
18
A142
ES09
DG
10
A11
FUSIBLE
LINK
RD
6
A0
ENGINE
STARTER
MOTOR
Z0
10
BK
FROM
ES11
OUTPUT
RELAY
DOWN
SHUT
AUTOMATIC
FUSED
B(+)
(8W-10-23)
(8W-10-9)
(8W-30-2)
(8W-30-2)
(8W-10-23)
(8W-21-2)
(8W-15-2)
8W - 20 - 2 8W-20 CHARGING SYSTEM
GAS
NS/GS
J988W-3 GS002002
BK/GY
6
A11
G103
Z0
2
BK
A0
6
RD
87
30
20A
FUSE
17
23
CENTER
DISTRIBUTION
POWER
BK
8
Z0
G100
BATTERY
DG/OR
16
A142
GENERATOR
45
MODULE
CONTROL
POWERTRAIN
5
C6
ES06
A142
18
DG/OR
DG/OR
18
A142
ES11
DG
10
A11
FUSIBLE
LINK
ENGINE
STARTER
MOTOR
Z0
10
BK
FROM
ES01
OUTPUT
RELAY
+
VOLTAGE
REGULATOR
1
RELAY
PLUG
GLOW
A0
10
RD
FUSIBLE
LINK
A54
16
DB
A54
10
RD
ES26
ES28
A0
2
RD
BS33
A142
16
DG/OR
1
7 E96
B108
A142
18
DG/OR
A142
18
DG/OR
DG/OR
18
A142
DG/OR
18
A142
DIESEL
RELAY
OUTPUT
A142
16
DG/OR
68
RELAY
OUTPUT
D+ DF
DIESEL
POWER
RELAY
POWER POWER
DIESEL
POWER
DIESEL
(8W-10-25)
(8W-10-9)
(8W-30-28)
(8W-10-25)
(8W-21-3)
(8W-15-3)
(8W-30-32)
(8W-30-28)
NS/GS 8W-20 CHARGING SYSTEM
DIESEL
8W - 20 - 3
GS002003 J988W-3
8W-21 STARTING SYSTEM
Component Page
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-21-2, 3
Cl utch I nterl ock Swi tch . . . . . . . . . . . . . . .8W-21-2, 3
Cl utch I nterl ock Swi tch Jumper . . . . . . . . . .8W-21-2
Engi ne Starter Motor . . . . . . . . . . . . . . . .8W-21-2, 3
Engi ne Starter Motor Rel ay . . . . . . . . . . .8W-21-2, 3
ES01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-21-3
ES26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-21-3
ES28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-21-3
Fuse 10 (JB) . . . . . . . . . . . . . . . . . . . . . . .8W-21-2, 3
Component Page
Fuse 23 (PDC). . . . . . . . . . . . . . . . . . . . . .8W-21-2, 3
Fusi bl e Li nk . . . . . . . . . . . . . . . . . . . . . . . . .8W-21-3
G100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-21-3
G103 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-21-3
Gl ow Pl ug Rel ay . . . . . . . . . . . . . . . . . . . . . .8W-21-3
Juncti on Bl ock . . . . . . . . . . . . . . . . . . . . . .8W-21-2, 3
Powertrai n Control Modul e . . . . . . . . . . . .8W-21-2, 3
NS/GS 8W - 21 STARTING SYSTEM 8W - 21 - 1
MOTOR
STARTER
ENGINE
1 2
C1 31
POWERTRAIN
CONTROL
MODULE
CONTROL
RELAY
MOTOR
STARTER
ENGINE
A0
6
RD
40A
FUSE
23
CENTER
DISTRIBUTION
POWER
ENGINE
STARTER
MOTOR
RELAY
3
C7
BR
12
T40
85 87
30 86
A0
6
RD
4
C6
3 C2
JUNCTION
BLOCK
C2
10
FUSE
10
10A
ST A41
2
1
CLUTCH
INTERLOCK
SWITCH
INTERLOCK
CLUTCH
MTX EATX
F45
20
YL/RD
1
2
BATTERY
M
1 PULL-IN
2 HOLD-IN
JUMPER
SWITCH
F45
20
YL/RD
T141
20
YL/RD
K90
18
TN
T141
20
YL/RD
(8W-30-6)
(8W-10-16)
(8W-10-8)
(8W-12-2)
(8W-12-16)
(8W-10-16)
(8W-20-2)
8W - 21 - 2 8W-21 STARTING SYSTEM
GAS
NS/GS
J988W-3 GS002102
RD
10
A54
ES28
ES26
DB
16
A54
LINK
FUSIBLE
RD
10
A0
RELAY
PLUG
GLOW
1
BK
6
Z0
BK
2
Z0
G100
G103
MOTOR
STARTER
ENGINE
K90
18
TN
1 2
A0
6
RD
40A
FUSE
23
CENTER
DISTRIBUTION
POWER
ENGINE
STARTER
MOTOR
RELAY
3
C7
BR
12
T40
85 87
30 86
A0
2
RD
4
C6
3 C2
JUNCTION
BLOCK
C2
10
FUSE
10
10A
ST A41
YL/RD
20
F45
1
2
M
1 PULL-IN
2 HOLD-IN
T141
20
YL/RD
6
E95
B107
3
MODULE
CONTROL
POWERTRAIN
K90
20
TN
TO
ES01
Z0
10
BK
ENGINE
STARTER
MOTOR
RELAY
CONTROL
FUSED
B(+)
SWITCH
INTERLOCK
CLUTCH
BATTERY
(8W-30-32)
(8W-10-16)
(8W-10-8)
(8W-12-2)
(8W-12-16)
(8W-10-16)
(8W-30-28)
(8W-15-3)
(8W-20-3)
NS/GS 8W-21 STARTING SYSTEM
DIESEL
8W - 21 - 3
GS002103 J988W-3
8W-30 FUEL/IGNITION SYSTEM
Component Page
A/C Compressor Cl utch Rel ay . . . . . . . . . . . . . . . .8W-30-5, 37
A/C Heater Control . . . . . . . . . . . . . . . . . . . .8W-30-5, 32, 37
A/C Pressure Transducer . . . . . . . . . . . . .8W-30-10, 16, 24, 38
Accel erator Pedal Posi ti on Sensor . . . . . . . . . . . . . . .8W-30-38
Ai rbag Control Modul e . . . . . . . . . . . . . . . . . . . .8W-30-4, 31
Al l Wheel Dri ve Sol enoi d . . . . . . . . . . . . . . . . . . . .8W-30-20
Automati c Shut Down Rel ay. . .8W-30-2, 7, 8, 9, 14, 15, 21, 22, 23
AW4 B13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-6
AW4 B13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-20
AWS1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-20
AWS2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-20
Back-Up Swi tch . . . . . . . . . . . . . . . . . . . . . . . .8W-30-6, 20
Battery . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-2, 3, 29, 32
Body Control Modul e. . . . . . . . . . . . .8W-30-4, 6, 20, 31, 36, 39
BS01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-39
BS02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-6, 20
BS05 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-4, 31
BS06 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-4, 31
BS30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-36
BS31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-28, 35
BS32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-33
BS33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-28
BS34. . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-33, 34, 36, 38
BS40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-35
BS41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-35
Camshaft Posi ti on Sensor . . . . . . . . . . . . . .8W-30-8, 14, 22, 24
Cl ockspri ng . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-5, 39
Cl utch Swi tch . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-39
Compass/Mi ni -Tri p Computer . . . . . . . . . . . . . . . . .8W-30-31
Control Sl eeve Sensor . . . . . . . . . . . . . . . . . . . . . .8W-30-34
Control l er Anti -Lock Brake . . . . . . . . . . . . . . . . .8W-30-4, 31
Crank Case Heater . . . . . . . . . . . . . . . . . . . . . . . .8W-30-29
Crankshaft Posi ti on Sensor . . . . . . . . . . . . . . .8W-30-8, 14, 22
Data Li nk Connector . . . . . . . . . . . . . . . . .8W-30-3, 4, 30, 31
Di esel Power Rel ay . . . . . . . . . . . . . . . . .8W-30-28, 29, 32, 33
Downstream Heated Oxygen Sensor . . . . . . . . . . . .8W-30-7, 21
EGR Sol enoi d. . . . . . . . . . . . . . . . . . . . . . .8W-30-18, 20, 29
Engi ne Cool ant Temperature Sensor . . . . . .8W-30-10, 16, 24, 36
Engi ne Speed Sensor . . . . . . . . . . . . . . . . . . . . . . .8W-30-35
Engi ne Starter Motor Rel ay. . . . . . . . . . . . . . .8W-30-6, 20, 28
ES01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-29
ES02. . . . . . . . . . . . .8W-30-8, 10, 11, 14, 16, 17, 22, 24, 25, 29
ES03 . . . . . . . . . . . . . . . . . . . . .8W-30-10, 11, 16, 17, 24, 25
ES05 . . . . . . . . . . . . . . . . . . .8W-30-14, 19, 22, 25, 33, 34, 36
ES06. . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-28, 29, 32, 33
ES07 . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-2, 18, 20, 26
ES08 . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-17, 19, 25
ES09 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-37
ES11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-2, 3
ES12 . . . . . . . . . . . . . . . . .8W-30-2, 7, 8, 9, 14, 15, 21, 22, 23
ES13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-4
ES14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-4
ES17 . . . . . . . . . . . . . . . . . . . . . . . .8W-30-8, 11, 14, 17, 22
ES18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-7, 21
ES21 . . . . . . . . . . . . . . . . . .8W-30-7, 8, 10, 11, 14, 16, 17, 24
ES24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-3
ES26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-32
ES28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-32
ES29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-32
ES30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-35
ES31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-35
ES37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-32
ES40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-29
ES99 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-9
Evap Leak Detecti on Pump . . . . . . . . . . . . . . . .8W-30-18, 26
Evap/Purge Sol enoi d . . . . . . . . . . . . . . . . . .8W-30-12, 18, 26
Fl exi bl e Fuel Sensor . . . . . . . . . . . . . . . . . . . . . . .8W-30-22
FS01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-16, 23
FS02 . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-16, 22, 24
FS03. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-15
Fuel Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-29
Fuel Heater Rel ay . . . . . . . . . . . . . . . . . . . . . . . .8W-30-29
Fuel I njector No. 1 . . . . . . . . . . . . . . . . . . . .8W-30-9, 15, 23
Fuel I njector No. 5 . . . . . . . . . . . . . . . . . . . . . . . .8W-30-23
Component Page
Fuel I njector No. 6 . . . . . . . . . . . . . . . . . . . . . . . .8W-30-23
Fuel Pump Modul e. . . . . . . . . . . . . . . . . . . . . .8W-30-33, 34
Fuel Pump Rel ay . . . . . . . . . . . . . . . . . . . . . . .8W-30-6, 20
Fuel Quanti ty Actuator . . . . . . . . . . . . . . . . . . . . .8W-30-33
Fuel Shutdown Sol enoi d. . . . . . . . . . . . . . . . . . . . .8W-30-33
Fuel Tank Modul e . . . . . . . . . . . . . . . . . . . . . . .8W-30-6, 20
Fuel Temperature Sensor . . . . . . . . . . . . . . . . . . . .8W-30-33
Fuel Ti mi ng Sol enoi d . . . . . . . . . . . . . . . . . . . . . .8W-30-33
Fuse 6 (JB). . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-32
Fuse 13 (PDC). . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-39
Fuse 16 (PDC) . . . . . . . . . . . . . . . . . . . . .8W-30-2, 6, 20, 29
Fuse 17 (PDC) . .8W-30-2, 7, 8, 9, 14, 15, 21, 22, 23, 28, 29, 32, 33
Fuse 28 (PDC) . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-3, 30
Fusi bl e Li nk A0 . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-32
G100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-2, 3, 29
G101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-7, 21
G103 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-2, 3, 29
G200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-3, 5, 30
G300 . . . . . . . . . . . . . . . . .8W-30-7, 13, 19, 21, 27, 28, 35, 39
G301 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-30, 35
G302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-6, 20
Generator . . . . . . . . . . . . . . . . . . . . . . .8W-30-2, 13, 19, 27
Gl ow Pl ug Lamp . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-32
Gl ow Pl ug No. 1. . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-32
Gl ow Pl ug No. 2. . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-32
Gl ow Pl ug No. 3. . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-32
Gl ow Pl ug No. 4. . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-32
Gl ow Pl ug Rel ay . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-32
I dl e Ai r Control Motor . . . . . . . . . . . . . . . . .8W-30-12, 18, 26
I gni ti on Coi l Pack . . . . . . . . . . . . . . . . . . . . .8W-30-8, 14, 22
I nstrument Cl uster . . . . . . . . . . . . . . . . . . . . . .8W-30-4, 31
I ntake Ai r Temperature Sensor . . . . . . . . . . . . . . . .8W-30-17
I ntake Ai r Temperature/Mani fol d Absol ute
Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . . 8W-30-10
Juncti on Bl ock . . . . . . . . . . . .8W-30-2, 3, 6, 13, 18, 19, 20, 26,
27, 28, 29, 30, 32, 36
Knock Sensor . . . . . . . . . . . . . . . . . . . . . . .8W-30-10, 16, 24
Left Front Park/Turn Si gnal Lamp . . . . . . . . . . . . . .8W-30-39
Left Headl amp Level i ng Motor . . . . . . . . . . . . . . . . .8W-30-39
Left Speed Control Swi tch . . . . . . . . . . . . . . . . . .8W-30-5, 39
Mani fol d Absol ute Pressure Sensor . . . . . . . . . . . .8W-30-16, 24
Memory Seat/Mi rror Modul e . . . . . . . . . . . . . . . .8W-30-3, 30
Message Center . . . . . . . . . . . . . . . . . . .8W-30-13, 19, 27, 32
Needl e Movement Sensor . . . . . . . . . . . . . . . . . . . .8W-30-35
Overhead Consol e . . . . . . . . . . . . . . . . . . . . . . .8W-30-4, 31
Power Di stri buti on Center .8W-30-2, 3, 5, 6, 7, 8, 9, 14, 15, 18, 20,
21, 22, 23, 26, 28, 29, 30, 32, 33, 36, 37, 39
Powertrai n Control Modul e . . . . . . . . . . . . . . . . . . .8W-30-10
Powertrai n Control Modul e .8W-30-2, 3, 4, 5, 6, 7, 8, 9, 14, 15, 16,
17, 18, 19, 20, 21, 22, 23, 24, 25, 26,
27, 28, 29, 30, 32, 33, 34, 35, 36, 37, 38, 39
PS01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-4, 31
PS02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-4, 31
PTC 1 (JB) . . . . . . . . . . . . . .8W-30-2, 6, 18, 20, 26, 28, 29, 36
Radi ator Fan Rel ay . . . . . . . . . . . . . . . . . . . . . . . .8W-30-5
Radi ator Fan Rel ay No. 1 . . . . . . . . . . . . . . . . . . . .8W-30-37
Radi o . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-3, 4, 30
Ri ght Speed Control Swi tch . . . . . . . . . . . . . . . . .8W-30-5, 39
Sentry Key I mmobi l i zer Modul e. . . . . . . . . . . . . . . . .8W-30-4
Servi ce Engi ne Soon Lamp . . . . . . . . . . . . . .8W-30-13, 19, 27
Stop Lamp Swi tch . . . . . . . . . . . . . . . . .8W-30-13, 19, 27, 39
Throttl e Posi ti on Sensor . . . . . . . . . . . . . . . .8W-30-11, 17, 25
Transmi ssi on Control Modul e . . . . . . .8W-30-3, 4, 17, 19, 25, 27
Transmi ssi on Range Sensor . . . . . . . . . .8W-30-6, 19, 20, 27, 34
Turbo Boost Pressure Sensor . . . . . . . . . . . . . . . . . .8W-30-34
Upstream Heated Oxygen Sensor . . . . . . . . . . . . .8W-30-7, 21
Vacuum Sol enoi d . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-27
Vehi cl e Speed Control Servo. . . . . . . . . . . . . .8W-30-13, 19, 27
Vehi cl e Speed Sensor . . . . . . . . . . . . . . . . . .8W-30-11, 17, 36
Vent Sol enoi d . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-27
NS/GS 8W - 30 FUEL/IGNITION SYSTEM 8W - 30 - 1
POWERTRAIN
CONTROL
MODULE
10
Z12
18 18
Z12
50
GROUND
46
B (+)
FUSED
C2
C2 C1
9A
PTC
1
C1 20
WT/BK
18
F87
GROUND
85 87
30 86
K51
18
DB/YL
67 C2 C1 6
DG/OR
18
A142
CONTROL
RELAY
DOWN
SHUT
AUTOMATIC AUTOMATIC
SHUT
DOWN
RELAY
OUTPUT
SWITCH
IGNITION
FUSED
BK/TN BK/TN
A14
18
RD/WT
ST-RUN A21
ES12
ES11
BK
10
Z0
BATTERY
JUNCTION
BLOCK
30
C1
F87
18
WT/BK
17
FUSE
20A
POWER
DISTRIBUTION
CENTER
BATT A0
8
C6
5
C6
A142
18
DG/OR
C6
9
20A
FUSE
16
6 C2
6
C6
ES07
F87
18
WT/BK
AUTOMATIC
SHUT
DOWN
RELAY
Z0
6
BK
G103 G100
BK
8
Z0
OUTPUT
(ST-RUN)
2
GENERATOR
GENERATOR
FIELD
DRIVER
C1 8
K20
18
DG
(8W-12-13)
(8W-10-16)
(8W-10-23)
(8W-15-2)
(8W-20-2)
(8W-12-2)
(8W-10-23)
(8W-10-9)
(8W-10-8)
(8W-10-26)
(8W-12-13)
(8W-20-2)
(8W-12-13)
8W - 30 - 2 8W-30 FUEL/IGNITION SYSTEM
GAS
NS/GS
J988W-3 GS003002
POWERTRAIN
CONTROL
MODULE
BK
10
Z0
BATTERY
28
FUSE
10A
POWER
DISTRIBUTION
CENTER
5
C3
BATT A0
13 C1
JUNCTION
BLOCK
17
C4
M1
20
PK
PK
20
M1
16
M1 20 PK
C1 7
B(+)
FUSED
RADIO
FUSED
B(+)
16 C1
MODULE
MIRROR
SEAT/
MEMORY
6
75 C2
RECEIVE
SCI
3
D20
18
LG
LG
20
D20
D20
20
LG PK
20
D21
B23
P18
E36
B33 4
SCI
C2 65
7
D21
20
PK
D21
18
PK
7
PK
18
D21
D21
18
PK
TRANSMIT
SCI
TRANSMIT
TRANSMISSION
CONTROL
MODULE
ES24
B70
E43
P34
B23
BK/WT
20
Z11
9
5 4
Z2
20
BK/LG
G200
1
Z11
20
BK/WT
Z11
18
BK/WT
ES11
CONNECTOR
LINK
DATA
M1 20 PK
MODULE
17
B17
16
B16
24
A24
Z0
6
BK
G103 G100
BK
8
Z0
EATX MTX
(8W-20-2)
(8W-10-11)
(8W-10-9)
(8W-10-8)
(8W-12-2)
(8W-47-2)
(8W-63-4)
(8W-31-8)
(8W-15-4)
(8W-15-2)
(8W-12-20)
NS/GS 8W-30 FUEL/IGNITION SYSTEM
GAS
8W - 30 - 3
GS003003 J988W-3
11 3
(+)
BUS
CCD CCD
BUS
(-)
D2
20
WT/BK
34 C2 C2 3
VT/BR
20
D1
(+)
BUS
CCD CCD
BUS
(-)
(+)
BUS
CCD CCD
BUS
(-)
19 20
(+)
BUS
CCD CCD
BUS
(-)
2 C3 C3 1
6 1
(-)
BUS
CCD CCD
BUS
(+)
(+)
BUS
CCD CCD
BUS
(-)
43 4
60 59 C2 C2
(-)
BUS
CCD CCD
BUS
(+)
14
RADIO
46
RECEIVE
SCI
(-)
BUS
CCD CCD
BUS
(+)
CLUSTER
INSTRUMENT
WT/BK
20
D2
VT/BR
20
D1
9 10
D1
20
VT/BR
D2
20
WT/BK
BRAKE
ANTI-LOCK
CONTROLLER
AIRBAG
CONTROL
MODULE
MODULE
CONTROL
BODY
4
C2 C2
3
D1
18
VT/BR WT/BK
18
D2
VT/BR
20
D1 D2
20
WT/BK
D2
20
WT/BK
D1
20
VT/BR
PS02
PS01
12 P18
B23
13
WT/BK
18
D2 D1
18
VT/BR
D2
18
WT/BK
VT/BR
18
D1
WT/BK
20
D2
D1
20
VT/BR
BS05
BS06
MODULE
CONTROL
TRANSMISSION
5 6 B75
C20
D2
18
WT/BK VT/BR
18
D1
CONSOLE
OVERHEAD
PK/LB
18
D6
WT/BK
18
D2 D1
18
VT/BR
POWERTRAIN
CONTROL
MODULE
7 B33
E36
2 6
D6
20
PK/LB
D2
18
WT/BK VT/BR
18
D1
14
D6
20
PK/LB
B14 B13 B12
PAIR
TWISTED
PAIR
TWISTED
PAIR
TWISTED
LINK
DATA
CONNECTOR
PAIR
TWISTED
PAIR
TWISTED
PAIR
TWISTED
EATX MTX MTX EATX
D2
18
WT/BK
D2
18
WT/BK
D1
18
VT/BR D1
18
VT/BR
ES13
ES14
D1
20
VT/BR
20
D2
5 6
TWISTED
PAIR
WT/BK
-EXPORT)
(BUILT-UP
MODULE
IMMOBILIZER
KEY
SENTRY
BUS
CCD
(-) (+)
BUS
CCD
(8W-47-2)
(8W-40-2)
(8W-35-3)
(8W-43-3)
(8W-45-3)
(8W-49-2)
(8W-31-8)
(8W-39-5)
GAS
NS/GS
J988W-3 GS003004
C2 64
POWERTRAIN
CONTROL
MODULE
CONTROL
RELAY
CLUTCH
COMPRESSOR
A/C
C13
18
DB/OR LG/DB
14
K173
RADIATOR
FAN
RELAY
73 C2
CONTROL
ST-RUN F87
POWER
DISTRIBUTION
CENTER
86
85
A/C
COMPRESSOR
CLUTCH
RELAY
7
C6
2
RADIATOR
FAN
RELAY
3
SIGNAL
C1 38
SWITCH
A/C
C103
20
DG/LB
A/C
SWITCH
SIGNAL
C1
B23
P18
E43
B70
1
DG/LB
20
C103
C103
18
DG/LB
3 4
CLOCKSPRING
18
8
B70
E43
P34
B23
RD/LG
20
V37
SPEED
CONTROL
SWITCH
41 C2
SIGNAL
V37
20
RD/LG
V37
RD/LG
Z2
20
BK/LG
G200
3
36
B36
21
A21
A/C
HEATER
CONTROL
V37
20
WT
Z2
20
BK
V37
22
WT
BK
22
Z2
1 RESUME/ACCEL
3 COAST
2 CANCEL
3
SWITCH
CONTROL
SPEED
RIGHT
2 1
1 2
2 ON/OFF
LEFT
SPEED
CONTROL
SWITCH
1 SET
WT
20
V37
C2 C2
CONTROL
RELAY
FAN
RADIATOR
(8W-10-26)
(8W-10-10)
(8W-42-7)
(8W-42-8)
(8W-15-4)
(8W-42-3)
GAS
8W - 30 - 5
GS003005 J988W-3
POWERTRAIN
CONTROL
MODULE
9A
PTC
1
85 87
30 86
K31
18
BR
74 C2
DG/WT
16
A141
CONTROL
RELAY
PUMP
FUEL
ST-RUN A21
JUNCTION
BLOCK
30
C1
F87
18
WT/BK
16
FUSE
20A
POWER
DISTRIBUTION
CENTER
BATT A0
3
C6
7
C2
6 C2
1
4 3
G4
18
DB
5
G302
GROUND
OUTPUT
RELAY
PUMP
FUEL FUEL
LEVEL
SENSOR
SIGNAL
MODULE
TANK
FUEL
C1
46
FUEL
LEVEL
SENSOR
SIGNAL
C6
4
C1 31
TN
18
K90
CONTROL
RELAY
MOTOR
STARTER
ENGINE
86
85
ENGINE
STARTER
MOTOR
RELAY
ST T141
FUEL
PUMP
RELAY
1
AW4
B13
Z1
14
BK
Z1
16
BK
MODULE
CONTROL
BODY
3
B13
AW4
G4
18
DB
B13
AW4
2
BACK-UP
LAMP
FEED
L1
20
VT/BK
2
B13
AW4
L1
20
VT/BK
BS02
EATX
VT/BK
18
L1
B33
E36
10
6
TRANSMISSION
RANGE
SENSOR
10
E36
B33
2
SWITCH
BACK-UP
L1
18
VT/BK
4
BACK-
UP
LAMP
FEED
BACK-
UP
LAMP
FEED
MTX
L1
20
VT/BK
L1
20
VT/BK
ST F45
C2 3
T141
20
YL/BK
F45
20
YL/BK
MTX EATX
(8W-12-13)
(8W-10-16)
(8W-12-2)
(8W-10-26)
(8W-10-8)
(8W-10-8)
(8W-15-13)
(8W-21-2)
(8W-45-7)
(8W-70-2)
(8W-31-3)
(8W-51-5)
(8W-12-16)
(8W-12-16)
(8W-12-13)
2.0L/2.4L
NS/GS
J988W-3 GS003006
POWERTRAIN
CONTROL
MODULE
GROUND
SENSOR
C2 43
87
30
17
FUSE
20A
BATT A0
5
C6
A142
18
DG/OR
AUTOMATIC
SHUT
DOWN
RELAY
CENTER
DISTRIBUTION
POWER
SENSOR
OXYGEN
HEATED
DOWNSTREAM
UPSTREAM
HEATED
OXYGEN
SENSOR
2
1 3
4
4
3 1
2
A142
18
DG/OR
DG/OR
18
A142
ES12
B70
E43
2
ES21
K4
18
BK/LB
ES18
G101
G300
3
51 C2
SIGNAL
SENSOR
OXYGEN
HEATED
DOWNSTREAM
10
B70
E43
K141
18
TN/WT
TN/WT
20
K141 K4
20
BK/LB BK/TN
20
Z12
UPSTREAM
HEATED
OXYGEN
SENSOR
SIGNAL
C1 30
BK/DG
18
K41
Z1
18
BK
BK
10
Z1
BK/LB
18
K4
1
B33
E36
K4
18
BK/LB
DG/OR
A142
18
(8W-10-23)
(8W-10-8)
(8W-30-2)
(8W-10-9)
(8W-10-23)
(8W-70-4)
(8W-70-5)
(8W-15-2)
(8W-15-2)
(8W-15-5)
2.0L/2.4L
8W - 30 - 7
GS003007 J988W-3
POWERTRAIN
CONTROL
MODULE
3 C1
DB/TN
18
K17
2
IGNITION
COIL
2 3
1
1
SENSOR
POSITION
CRANKSHAFT
K4
18
BK/LB
C2 43
SENSOR
GROUND
ES02
ES21
BK/LB
K4
K24
18
GY/BK
C1 32
SIGNAL
SENSOR
POSITION
CRANKSHAFT
POSITION
SENSOR
SIGNAL GROUND
SENSOR
SENSOR
GROUND
2
3
8V
SUPPLY
C2
OR
18
K7
SIGNAL
SENSOR
POSITION
CAMSHAFT
POSITION
SENSOR
SIGNAL
33 C1
TN/YL
18
K44
SENSOR
POSITION
CAMSHAFT
ES17
K7
18
OR
K7
18
OR
K4
BK/LB
SUPPLY
8V
8V
SUPPLY
87
30
DG/OR
18
A142
ES12
17
FUSE
20A
BATT A0
5
C6
A142
18
DG/OR
AUTOMATIC
SHUT
DOWN
RELAY
3 1
DRIVER
NO.2
COIL
IGNITION
K19
18
GY/RD
C1 11
CENTER
DISTRIBUTION
POWER
PACK
44
18
18
18
K4
BK/LB
CRANCKSHAFT
CAMSHAFT
DRIVER
NO.1
COIL
IGNITION
(8W-70-4)
(8W-70-4)
(8W-70-9)
(8W-10-23)
(8W-10-23)
(8W-10-8)
(8W-30-2)
(8W-10-9)
2.0L
NS/GS
J988W-3 GS003008
POWERTRAIN
CONTROL
MODULE
1
2
DRIVER
NO. 1
INJECTOR
C1 13
NO. 1
INJECTOR
FUEL
K11
18
WT/DB
DG/OR
18
A142
ES99
A142
DG/OR
TN/WT
18
K12
FUEL
INJECTOR
NO. 2
17
INJECTOR
NO. 2
DRIVER
2
1
A142
DG/OR
YL/WT
18
K13
FUEL
INJECTOR
NO. 3
7
INJECTOR
NO. 3
DRIVER
2
1
A142
DG/OR
LB/BR
18
K14
FUEL
INJECTOR
NO. 4
16
INJECTOR
NO. 4
DRIVER
2
1
C1 C1 C1
87
30
ES12
17
FUSE
20A
BATT A0
5
C6
A142
18
DG/OR
AUTOMATIC
SHUT
DOWN
RELAY
CENTER
DISTRIBUTION
POWER
18 18 18
A142
18
DG/OR
(8W-10-23)
(8W-10-23)
(8W-10-8)
(8W-30-2)
(8W-10-9)
2.0L
8W - 30 - 9
GS003009 J988W-3
POWERTRAIN
CONTROL
MODULE
K4
18
BK/LB
C2 43
SENSOR
GROUND
ES21
2
1
KNOCK
SENSOR
SIGNAL
C1 25
DB/LG
18
K42
KNOCK
SENSOR
K6
18
VT/WT
61 C2
SUPPLY
5V
D
C
A
C1 36
DG/RD
18
K1
BK/LB
18
K4
A/C
PRESSURE
TRANSDUCER
K4
18
BK/LB
1
2
3
SENSOR
GROUND
A/C
PRESSURE
SIGNAL
SUPPLY
5V
C18
18
DB
C2 42
SIGNAL
PRESSURE
A/C
ES02
18
K4
BK/LB BK/LB
K4
18
K2
18
TN/BK
26 C1
2
1
SENSOR
TEMPERATURE
COOLANT
ENGINE
ES03
BK/LB
K4
18
K6
18
VT/WT
K6
18
VT/WT
SIGNAL
SENSOR
PRESSURE
ABSOLUTE
MANIFOLD
SIGNAL
SENSOR
TEMPERATURE
COOLANT
ENGINE INTAKE
AIR
TEMPERATURE
SENSOR
SIGNAL
K21
18
BK/RD
37 C1
B
GROUND
SENSOR
5V
SUPPLY
TEMPERATURE
SENSOR
SIGNAL SIGNAL
SENSOR
MAP
PRESSURE
SENSOR
INTAKE
AIR
TEMPERATURE/
MANIFOLD
ABSOLUTE
AIR
INTAKE
(8W-70-4)
(8W-70-4)
(8W-70-7)
2.0L
NS/GS
J988W-3 GS003010
POWERTRAIN
CONTROL
MODULE
K4
18
BK/LB
C2 43
SENSOR
GROUND
ES02
ES21
K6
18
VT/WT
61 C2
SUPPLY
5V
2
3
1
C1 35
BK/LB
18
K4
SENSOR
POSITION
THROTTLE
K4
18
BK/LB
WT/OR
18
G7
2 3
SENSOR
GROUND
SENSOR
SIGNAL
C2 66
BK/LB
K4
18
K6
18
VT/WT
OR/DB
18
K22
SENSOR
SPEED
VEHICLE
8V
SUPPLY
44 C2
SUPPLY
8V
1
K7
18
OR
ES17
K7
18
OR
ES03
SIGNAL
SENSOR
POSITION
THROTTLE VEHICLE
SPEED
SENSOR
SIGNAL
SPEED
VEHICLE
(8W-70-4)
(8W-70-4) (8W-70-9)
(8W-70-7)
2.0L
8W - 30 - 11
GS003011 J988W-3
POWERTRAIN
CONTROL
MODULE
C2 68
PK/BK
18
K52
CONTROL
SOLENOID
EVAP/PURGE
2
1
SOLENOID
PURGE
EVAP/
57 C2 C2 49 C2 48 C2 58
3 4
MOTOR
CONTROL
AIR
IDLE
MOTOR
NO.1
DRIVER
2 1
K39
18
GY/RD
K60
18
YL/BK
K40
18
BR/WT
K59
18
VT/BK
C2 70
K70
18
VT/RD
CONTROL
AIR
IDLE IDLE
AIR
CONTROL
DRIVER
NO.2
MOTOR
IDLE
AIR
CONTROL
DRIVER
NO.3
MOTOR
IDLE
AIR
CONTROL
DRIVER
NO.4
MOTOR
MOTOR
NO.4
DRIVER
CONTROL
AIR
IDLE
MOTOR
NO.3
DRIVER
CONTROL
AIR
IDLE
MOTOR
NO.2
DRIVER
CONTROL
AIR
IDLE IDLE
AIR
DRIVER
NO.1
MOTOR
CONTROL MODULATED
PURGE
CURRENT
SENSE
WIDTH
PULSE
2.0L
NS/GS
J988W-3 GS003012
POWERTRAIN
CONTROL
MODULE
SERVO
CONTROL
SPEED
VEHICLE
1 3
4
STOP
LAMP
SWITCH
V30
18
DB/RD
2 1 3
C2
80
VENT
SOLENOID SOLENOID
VACUUM
56
C2
V35
18
LG/RD TN/RD
18
V36
3
E43
B70
7
E43
B70
6
YL/RD
18
V32
5
C1 C2
62
K29
18
WT/PK
SPEED
CONTROL
VACUUM
SOLENOID
CONTROL CONTROL
SOLENOID
VENT
CONTROL
SPEED
WT/PK
20
K29 V32
20
YL/RD
STOP LAMP
SWITCH
SENSE
SPEED
CONTROL
ON/OFF
SWITCH SENSE
2
6
G300
BK
20
Z1
DB/RD
20
V30
K20
18
DG
8 C1
2
GENERATOR
7
ST-RUN V23
CENTER
MESSAGE
SERVICE
ENGINE
SOON
LAMP
C1 22
5
B70
E43
P34
B23
2
A2
G3
20
BK/PK
BK/PK
20
G3
BK/PK
18
G3
LAMP DRIVER
SOON INDICATOR
ENGINE
SEVICE
DRIVER
FIELD
GENERATOR
*13
* RHD
RHD LHD
JUNCTION
BLOCK
TO
Z1
20
BK
GENERATOR
FIELD
DRIVER
(8W-33-3)
(8W-33-3)
(8W-15-7)
(8W-20-2)
(8W-12-9)
(8W-46-3)
(8W-12-19)
2.0L
8W - 30 - 13
GS003013 J988W-3
POWERTRAIN
CONTROL
MODULE
3 C1
DB/TN
18
K17
2
IGNITION
COIL
2 3
1
1
SENSOR
POSITION
CRANKSHAFT
K4
18
BK/LB
C2 43
SENSOR
GROUND
ES02
ES21
BK/LB
K4
K24
18
GY/BK
C1 32
SIGNAL
SENSOR
POSITION
CRANKSHAFT
POSITION
SENSOR
SIGNAL GROUND
SENSOR
SENSOR
GROUND
2
3
8V
SUPPLY
C2
OR
18
K7
SIGNAL
SENSOR
POSITION
CAMSHAFT
POSITION
SENSOR
SIGNAL
33 C1
TN/YL
18
K44
SENSOR
POSITION
CAMSHAFT
ES17
K7
18
OR
K7
18
OR
K4
BK/LB
SUPPLY
8V
8V
SUPPLY
87
30
DG/OR
18
A142
ES12
17
FUSE
20A
BATT A0
5
C6
A142
18
DG/OR
AUTOMATIC
SHUT
DOWN
RELAY
3 1
DRIVER
NO. 2
COIL
IGNITION
K19
18
GY/RD
C1 11
CENTER
DISTRIBUTION
POWER
PACK
44
18 18
ES05
GY/BK
18
K24
EATX MTX
IGNITION
COIL
NO. 1
DRIVER
CRANKSHAFT
CAMSHAFT
(8W-70-5)
(8W-70-5)
(8W-70-9)
(8W-10-23)
(8W-10-23)
(8W-10-8)
(8W-30-2)
(8W-10-9)
(8W-70-8)
2.4L
NS/GS
J988W-3 GS003014
POWERTRAIN
CONTROL
MODULE
1
2
DRIVER
NO. 1
INJECTOR
C1 13
NO. 1
INJECTOR
FUEL
K11
18
WT/DB
DG/OR
18
A142
FS03
10
A142
DG/OR
TN/WT
18
K12
FUEL
INJECTOR
NO. 2
17
INJECTOR
NO. 2
DRIVER
2
1
A142
DG/OR
YL/WT
18
K13
FUEL
INJECTOR
NO. 3
7
INJECTOR
NO. 3
DRIVER
2
1
A142
DG/OR
LB/BR
18
K14
FUEL
INJECTOR
NO. 4
16
INJECTOR
NO. 4
DRIVER
2
1
DG/OR
18
A142
1 2 3 4
E69
F09
C1 C1 C1
K14
18
LB/BR
K13
18
YL/WT
K12
18
TN/WT WT/DB
18
K11
87
30
ES12
17
FUSE
20A
BATT A0
5
C6
A142
18
DG/OR
AUTOMATIC
SHUT
DOWN
RELAY
CENTER
DISTRIBUTION
POWER
E69
F09
18 18 18
(8W-10-23)
(8W-10-23)
(8W-10-8)
(8W-30-2)
(8W-10-9)
2.4L
8W - 30 - 15
GS003015 J988W-3
POWERTRAIN
CONTROL
MODULE
K4
18
BK/LB
C2 43
SENSOR
GROUND
ES02
ES21
BK/LB
K4
18
2
1
KNOCK
SENSOR
SIGNAL
C1 25
DB/LG
18
K42
KNOCK
SENSOR
K6
18
VT/WT
61 C2
SUPPLY
5V
ES03
8
C
B
A
11
F09
E69
C1 36
DG/RD
18
K1
K1
18
DG/RD BK/LB
18
K4
SENSOR
PRESSURE
ABSOLUTE
MANIFOLD A/C
PRESSURE
TRANSDUCER
K4
18
BK/LB DB
18
C18
1
2
3
SENSOR
GROUND
A/C
PRESSURE
SWITCH
SIGNAL
SUPPLY
5V
E69
F09
9
C18
18
DB
C2 42
SIGNAL
SWITCH
PRESSURE
A/C
FS01
18
K4
BK/LB
BK/LB
K4
18
K2
18
TN/BK
26 C1
2
1
SENSOR
TEMPERATURE
COOLANT
ENGINE
12
TN/BK
18
K2
FS02
VT/WT
18
K6
BK/LB
K4
18
5
K6
18
VT/WT
K6
18
VT/WT
K6
18
VT/WT
SIGNAL
SENSOR
PRESSURE
ABSOLUTE
MANIFOLD
SIGNAL
SENSOR
TEMPERATURE
COOLANT
ENGINE
(8W-70-5)
(8W-70-5)
(8W-70-7)
(8W-70-5)
(8W-70-7)
2.4L
NS/GS
J988W-3 GS003016
POWERTRAIN
CONTROL
MODULE
K4
18
BK/LB
C2 43
SENSOR
GROUND
ES02
ES21
K6
18
VT/WT
61 C2
SUPPLY
5V
2
3
1
C1 35
K22
18
OR/DB BK/LB
18
K4
SENSOR
POSITION
THROTTLE
K4
18
BK/LB
WT/OR
18
G7
2 3
SENSOR
GROUND
VSS
SIGNAL
C2 66
BK/LB
K4
18
K21
18
BK/RD
37 C1
2
1
SENSOR
TEMPERATURE
AIR
INTAKE
BK/LB
K4
18
K6
18
VT/WT
OR/DB
18
K22
ES08
SENSOR
SPEED
VEHICLE
8V
SUPPLY
44 C2
SUPPLY
8V
1
K7
18
OR
ES17
K7
18
OR
G7
18
WT/OR
EATX MTX
WT/OR
18
G7
SIGNAL
SENSOR
58
MODULE
CONTROL
TRANSMISSION
ES03
SIGNAL
SENSOR
POSITION
THROTTLE INTAKE
AIR
TEMPERATURE
SENSOR
SIGNAL
VEHICLE
SPEED
SENSOR
SIGNAL
(EATX)
SPEED
VEHICLE
(8W-70-5)
(8W-70-5) (8W-70-9)
(8W-31-4)
(8W-70-7)
(8W-70-8)
2.4L
8W - 30 - 17
GS003017 J988W-3
POWERTRAIN
CONTROL
MODULE
9A
PTC
1
C2 68
PK/BK
18
K52
ST-RUN A21
JUNCTION
BLOCK
30
C1
F87
18
WT/BK
POWER
DISTRIBUTION
CENTER
6 C2
6
C6
F87
18
WT/BK
2
1
SOLENOID
PURGE
EVAP/
E69
F09
7
K52
18
PK/BK
ES07
F87
18
WT/BK
GY/YL
18
K35
1
2
EGR
SOLENOID
CONTROL
40 C1 C2 72
PUMP
DETECTION
LEAK
EVAP
3
1
K107
18
YL/BK
WT/BK
18
F87
WT/DG
18
K106
2
77 C2
PUMP
DETECTION
LEAK
SENSE
SWITCH SOLENOID
CONTROL
LEAK
DETECTION
PUMP
(ST-RUN)
IGN.
FUSE
SOLENOID
CONTROL SENSE
SWITCH
57 C2 C2 49 C2 48 C2 58
3 4
MOTOR
CONTROL
AIR
IDLE
MOTOR
NO. 1
DRIVER
2 1
K39
18
GY/RD
K60
18
YL/BK
K40
18
BR/WT
K59
18
VT/BK
70 C2
6
K70
18
VT/RD
K70
18
VT/RD
(MTX)
SOLENOID
EGR
EVAP/
PURGE
SOLENOID
CONTROL PURGE
MODULATED
WIDTH
PULSE
CONTROL
AIR
IDLE
DRIVER
NO. 2
MOTOR
CONTROL
AIR
IDLE
DRIVER
NO. 3
MOTOR
CONTROL
AIR
IDLE
DRIVER
NO. 4
MOTOR
CONTROL
AIR
IDLE
IDLE
AIR
CONTROL
MOTOR
NO. 4
DRIVER
IDLE
AIR
CONTROL
MOTOR
NO. 3
DRIVER
IDLE
AIR
CONTROL
MOTOR
NO. 2
DRIVER
IDLE
AIR
DRIVER
NO. 1
MOTOR
CONTROL
CURRENT
SENSE
PUMP
DETECTION
LEAK
DETECTION
LEAK
PUMP
BUILT-UP
-EXPORT)
(EXCEPT
(8W-12-13)
(8W-10-16)
(8W-12-2)
(8W-10-29)
(8W-12-13)
2.4L
NS/GS
J988W-3 GS003018
POWERTRAIN
CONTROL
MODULE
C1 35
K22
18
OR/DB
OR/DB
18
K22
ES08
MODULE
CONTROL
TRANSMISSION
12
SIGNAL
SENSOR
POSITION
THROTTLE
THROTTLE
POSITION
SENSOR
SIGNAL SIGNAL
SENSOR
POSITION
CRANKSHAFT
CRANKSHAFT
POSITION
SENSOR
SIGNAL
6
ES05
K24
18
GY/BK
GY/BK
18
K24
32 C1
BK/YL
18
T41
76
C2
10
P/N
TRANSMISSION
RANGE
SENSOR
SERVO
CONTROL
SPEED
VEHICLE
1 3
4
STOP
LAMP
SWITCH
V30
18
DB/RD
2 1 3
C2
80
VENT
SOLENOID SOLENOID
VACUUM
56
C2
V35
18
LG/RD TN/RD
18
V36
3
E43
B70
7
E43
B70
6
YL/RD
18
V32
5
C1 C2
62
K29
18
WT/PK
SPEED
CONTROL
VACUUM
SOLENOID
CONTROL CONTROL
SOLENOID
VENT
CONTROL
SPEED
WT/PK
20
K29 V32
20
YL/RD
STOP LAMP
SWITCH
SENSE
SPEED
CONTROL
ON/OFF
SWITCH SENSE
2
6
G300
BK
20
Z1
DB/RD
20
V30
GENERATOR
FIELD DRIVER
K20
18
DG
8 C1
2
GENERATOR
TRANSMISSION
RANGE
SWITCH
T41
SENSE
10
YL/DG
18
T10
SENSE
REQUEST
MANAGEMENT
TORQUE
TORQUE
MANAGEMENT
REQUIREMENT
SENSE
63 C2
7
ST-RUN V23
CENTER
MESSAGE
SERVICE
ENGINE
SOON
LAMP
C1 22
INDICATOR
SERVICE ENGINE SOON
5
B70
E43
P34
B23
2
A2
G3
20
BK/PK
BK/PK
20
G3
BK/PK
18
G3
*13
* RHD
RHD LHD
JUNCTION
BLOCK
TO
GENERATOR
FIELD
DRIVER
LAMP DRIVER
(8W-70-8) (8W-70-8)
(8W-31-5)
(8W-33-3)
(8W-33-3)
(8W-15-7)
(8W-20-2)
(8W-31-4)
(8W-31-8)
(8W-12-9)
(8W-46-3)
(8W-12-19)
2.4L
8W - 30 - 19
GS003019 J988W-3
POWERTRAIN
CONTROL
MODULE
9A
PTC
1
85 87
30 86
K31
18
BR
74 C2
DG/WT
16
A141
CONTROL
RELAY
PUMP
FUEL
ST-RUN A21
JUNCTION
BLOCK
30
C1
F87
18
WT/BK
16
FUSE
20A
POWER
DISTRIBUTION
CENTER
BATT A0
3
C6
7
C2
6 C2
1
4 3
G4
18
DB
5
G302
GROUND
OUTPUT
RELAY
PUMP
FUEL FUEL
LEVEL
SENSOR
SIGNAL
MODULE
TANK
FUEL
C1
46
FUEL
LEVEL
SENSOR
SIGNAL
C6
6
EGR
SOLENOID
CONTROL
C1 40
GY/YL
18
K35
2
1
ES07
F87
18
WT/BK
WT/BK
18
F87
FUEL
PUMP
RELAY
C6
4
C1 31
TN
18
K90
CONTROL
RELAY
MOTOR
STARTER
ENGINE
86
85
ENGINE
STARTER
MOTOR
RELAY
ST F45
4
AW4
B13 3
B13
AW4
1
1
SOLENOID
DRIVE
WHEEL
ALL
1
C2 C1
BODY
CONTROL
MODULE
EGR
SOLENOID
3.8L 3.3L
Z1
16
BK
Z1
16
BK
Z1
16
BK
Z1
18
BK
Z1
18
BK
AWS1
GROUND GROUND
Z1 14BK
2
BACK-UP
SWITCH
SENSE
AWS2
2
B13
AW4
BS02
L1
20
VT/BK
VT/BK
20
L1
VT/BK
20
L1
MTX
FEED
LAMP
UP
BACK-
FEED
LAMP
UP
BACK-
VT/BK
18
L1
BACK-UP
SWITCH
2
B33
E36
10
SENSOR
RANGE
TRANSMISSION
6
10
E36
B33
L1
18
VT/BK
EATX
(8W-12-13)
(8W-10-16)
(8W-12-2)
(8W-10-26)
(8W-10-8)
(8W-10-9)
(8W-10-8)
(8W-15-13)
(8W-12-13)
(8W-21-2)
(8W-12-16)
(8W-31-3)
(8W-45-7)
(8W-31-3)
(8W-70-2)
(8W-51-5)
(8W-31-3)
3.3L/3.8L
NS/GS
J988W-3 GS003020
POWERTRAIN
CONTROL
MODULE
GROUND
SENSOR
C2 43
87
30
17
FUSE
20A
BATT A0
5
C6
A142
18
DG/OR
AUTOMATIC
SHUT
DOWN
RELAY
CENTER
DISTRIBUTION
POWER
SENSOR
OXYGEN
HEATED
DOWNSTREAM
UPSTREAM
HEATED
OXYGEN
SENSOR
2
1 3
4
3 1
2
A142
18
DG/OR
DG/OR
18
A142
ES12
B70
E43
2
ES02
K4
18
BK/LB
ES18
G101
G300
3
51 C2
SIGNAL
SENSOR
OXYGEN
HEATED
10
B70
E43
K141
18
TN/WT
TN/WT
20
K141
K4
20
BK/LB BK/TN
20
Z12
HEATED
OXYGEN
SENSOR
SIGNAL
C1 30
BK/DG
18
K41
Z1
18
BK
BK
10
Z1
BK/LB
18
K4
1
B33
E36
BK/LB
18
K4
4
18
DG/OR
A142
(8W-10-23)
(8W-10-8)
(8W-30-2)
(8W-10-9)
(8W-10-23)
(8W-70-6)
(8W-15-2)
(8W-15-2)
(8W-15-5)
3.3L/3.8L
8W - 30 - 21
GS003021 J988W-3
POWERTRAIN
CONTROL
MODULE
11 C1
2 3
1
1
SENSOR
POSITION
CRANKSHAFT
K4
18
BK/LB
C2 43
SENSOR
GROUND
ES02
K24
18
GY/BK
C1 32
SIGNAL
SENSOR
POSITION
CRANKSHAFT
POSITION
SENSOR
SIGNAL GROUND
SENSOR
SENSOR
GROUND
2
3
8V
SUPPLY
C2
OR
18
K7
SIGNAL
SENSOR
CAMSHAFT
POSITION
SENSOR
SIGNAL
33 C1
TN/YL
18
K44
SENSOR
POSITION
CAMSHAFT
ES17
K7
18
OR
K7
18
OR
SUPPLY
8V
8V
SUPPLY
87
30
DG/OR
18
A142
ES12
17
FUSE
20A
BATT A0
5
C6
A142
18
DG/OR
AUTOMATIC
SHUT
DOWN
RELAY
CENTER
DISTRIBUTION
POWER
1 2
3
4
PACK
COIL
IGNITION
C1 3 2 C1
IGNITION
COIL
NO. 1
DRIVER DRIVER
NO. 2
COIL
IGNITION IGNITION
COIL
NO. 3
DRIVER
K18
18
RD/YL DB/TN
18
K17 K19
18
GY/RD
18
K4
BK/LB
44
ES05
K24
18
GY/BK
(3.3L/
SENSOR
FUEL
FLEXIBLE
ETHANOL)
SUPPLY
8V
1
SENSOR
GROUND
2 3
SIGNAL
SENSOR
54 C2
K4
18
BK/LB
K50
18
YL/WT
K7
18
OR
F02
E78
7
8
F02
E78
FS02
14
F02
E78
K4
18
BK/LB
K4
18
BK/LB
K44
18
TN/YL
K7
18
OR
CRANKSHAFT
FUEL
FLEXIBLE
CRANKSHAFT
POSITION
FLEXIBLE
FUEL
SENSOR
SIGNAL
(8W-70-6)
(8W-10-23)
(8W-10-23)
(8W-10-8)
(8W-30-2)
(8W-10-9)
(8W-70-8)
(8W-70-6)
3.3L/3.8L
NS/GS
J988W-3 GS003022
POWERTRAIN
CONTROL
MODULE
DRIVER
NO. 1
INJECTOR
C1 13
NO. 1
INJECTOR
FUEL
K11
18
WT/DB
DG/OR
18
A142
1
A142
DG/OR
TN/WT
18
K12
FUEL
INJECTOR
NO. 2
17
INJECTOR
NO. 2
DRIVER
A142
DG/OR
YL/WT
18
K13
FUEL
INJECTOR
NO. 3
7
INJECTOR
NO. 3
DRIVER
A142
DG/OR
LB/BR
18
K14
FUEL
INJECTOR
NO. 4
16
INJECTOR
NO. 4
DRIVER
DG/OR
18
A142
3 4 5 6
C1 C1 C1
87
30
ES12
17
FUSE
20A
BATT A0
5
C6
A142
18
DG/OR
AUTOMATIC
SHUT
DOWN
RELAY
CENTER
DISTRIBUTION
POWER
E78
F02
18 18 18 18
C1
F02
E78
13
2
1
DRIVER
NO. 6
INJECTOR
14
NO. 6
INJECTOR
FUEL
K58
18
BR/DB
DG/OR
A142
NO. 5
INJECTOR
FUEL
A142
DG/OR
18
12
C1
DRIVER
NO. 5
INJECTOR
15
K38
18
GY
2
1
2
1
2
1
2
1
2
1
DG/OR
A142
18
FS01
(8W-10-23)
(8W-10-23)
(8W-10-8)
(8W-30-2)
(8W-10-9)
(8W-10-24)
3.3L/3.8L
8W - 30 - 23
GS003023 J988W-3
POWERTRAIN
CONTROL
MODULE
K4
18
BK/LB
C2 43
SENSOR
GROUND
ES02
BK/LB
K4
18
2
1
KNOCK
SENSOR
SIGNAL
C1 25
DB/LG
18
K42 K6
18
VT/WT
61 C2
SUPPLY
5V
C
B
A
10
F02
E78
C1 36
DG/RD
18
K1
K1
18
DG/RD BK/LB
18
K4
SENSOR
PRESSURE
ABSOLUTE
MANIFOLD A/C
PRESSURE
TRANSDUCER
K4
18
BK/LB
1
2
3
SENSOR
GROUND
A/C
PRESSURE
SIGNAL
SUPPLY
5V
C18
18
DB
C2 42
PRESSURE
A/C
18
K4
BK/LB
BK/LB
K4
18
K2
18
TN/BK
26 C1
2
1
SENSOR
TEMPERATURE
COOLANT
ENGINE
ES03
14
K6
18
VT/WT
K6
18
VT/WT
FS02
E78
F02
11
TN/BK
18
K2
SENSOR
TEMPERATURE
COOLANT
ENGINE
SIGNAL
SENSOR
PRESSURE
ABSOLUTE
MANIFOLD
E78
F02
2
E78
F02
ES21
18
K4
BK/LB
(3.8L)
SENSOR
KNOCK
2
CAMSHAFT
POSITION
SENSOR
K4
18
BK/LB
SENSOR
GROUND
SIGNAL
SIGNAL
(8W-70-6)
(8W-70-7)
(8W-70-6)
(8W-30-22)
3.3L/3.8L
NS/GS
J988W-3 GS003024
POWERTRAIN
CONTROL
MODULE
K4
18
BK/LB
C2 43
SENSOR
GROUND
ES02
K6
18
VT/WT
61 C2
SUPPLY
5V
2
3
1
K22
18
OR/DB BK/LB
18
K4
SENSOR
POSITION
THROTTLE
WT/OR
18
G7
C2 66
58
MODULE
CONTROL
TRANSMISSION
ES03
VT/WT
18
K6
SIGNAL
SENSOR
SPEED
VEHICLE
VEHICLE
SPEED
SENSOR
SIGNAL SIGNAL
SENSOR
POSITION
CRANKSHAFT
CRANKSHAFT
POSITION
SENSOR
SIGNAL
6
32 C1
K24
18
GY/BK
ES05
12
THROTTLE
POSITION
SENSOR
SIGNAL
K24
18
GY/BK OR/DB
18
K22
ES08
C1 35
SIGNAL
SENSOR
POSITION
THROTTLE
K22
18
OR/DB
(8W-70-6) (8W-70-7)
(8W-31-4)
(8W-70-8)
3.3L/3.8L
8W - 30 - 25
GS003025 J988W-3
POWERTRAIN
CONTROL
MODULE
9A
PTC
1
C2 68
PK/BK
18
K52
SOLENOID
PURGE
EVAP/
ST-RUN A21
JUNCTION
BLOCK
30
C1
F87
18
WT/BK
POWER
DISTRIBUTION
CENTER
6 C2
6
C6
F87
18
WT/BK
2
1
SOLENOID
PURGE
EVAP/
ES07
C2 72
PUMP
DETECTION
LEAK
EVAP
3
1
K107
18
DB/WT
WT/BK
18
F87
WT/DG
18
K106
2
77 C2
(ST-RUN)
IGN.
FUSE
SOLENOID
CONTROL SENSE
SWITCH
57 C2 C2 49 C2 48 C2 58
3 4
MOTOR
CONTROL
AIR
IDLE
MOTOR
NO. 1
DRIVER
2 1
K39
18
GY/RD
K60
18
YL/BK
K40
18
BR/WT
K59
18
VT/BK
SENSE
SWITCH
PUMP
DETECTION
LEAK LEAK
DETECTION
PUMP
SOLENOID
CONTROL
PULSE
WIDTH
MODULATED
PURGE
70 C2
BUILT-UP
-EXPORT)
(EXCEPT
K70
18
VT/RD
CONTROL
CONTROL
AIR
IDLE IDLE
AIR
CONTROL
NO. 2
MOTOR MOTOR
NO. 4
CONTROL
AIR
IDLE IDLE
AIR
CONTROL
NO. 3
MOTOR
PUMP
DETECTION
LEAK
PUMP
DETECTION
LEAK
MOTOR
NO. 3
CONTROL
AIR
IDLE IDLE
AIR
CONTROL
NO. 4
MOTOR MOTOR
NO. 2
CONTROL
AIR
IDLE IDLE
AIR
CONTROL
DRIVER
NO. 1
MOTOR
CURRENT
DRIVER DRIVER DRIVER
DRIVER DRIVER DRIVER SENSE
(8W-12-13)
(8W-10-16)
(8W-12-2)
(8W-10-29)
(8W-12-13)
3.3L/3.8L
NS/GS
J988W-3 GS003026
POWERTRAIN
CONTROL
MODULE
BR/YL
18
T41
76
C2
TRANS
RANGE
SWITCH
T41
SENSE
P/N
10
SERVO
CONTROL
SPEED
VEHICLE
1 3
4
STOP
LAMP
SWITCH
V30
18
DB/RD
2 1 3
C2
80
VENT
SOLENOID SOLENOID
VACUUM
56
C2
V35
18
LG/RD TN/RD
18
V36
3
E43
B70
7
E43
B70
6
YL/RD
18
V32
5
C1 C2
62
K29
18
WT/PK
SPEED
CONTROL
VACUUM
SOLENOID
CONTROL CONTROL
SOLENOID
VENT
CONTROL
SPEED
WT/PK
20
K29 V32
20
YL/RD
STOP
LAMP
SWITCH
SENSE
SPEED
CONTROL
ON/OFF
SWITCH
SENSE
2
6
G300
BK
20
Z1
DB/RD
20
V30
TRANSMISSION
RANGE
SENSOR
2
8 C1
K20
18
DG
DRIVER
FIELD
GENERATOR
GENERATOR
7
ST-RUN V23
CENTER
MESSAGE
SERVICE
ENGINE
SOON
LAMP
C1 22
INDICATOR LAMP DRIVER
SERVICE ENGINE SOON
5
B70
E43
P34
B23
2
A2
G3
20
BK/PK
BK/PK
20
G3
BK/PK
18
G3
*13
RHD LHD
JUNCTION
BLOCK
TO
* RHD
GENERATOR
FIELD
DRIVER
10
TRANSMISSION
CONTROL
MODULE
C2 63
T10
18
YL/DG
TORQUE
MANAGEMENT
REQUIREMENT
SENSE
SENSE
REQUIREMENT
MANAGEMENT
TORQUE
(8W-33-3)
(8W-33-3)
(8W-15-7)
(8W-31-5)
(8W-20-2)
(8W-12-9)
(8W-46-3)
(8W-12-19)
(8W-31-8)
3.3L/3.8L
8W - 30 - 27
GS003027 J988W-3
POWERTRAIN
CONTROL
MODULE
46
14
Z12
1
GROUND
9A
PTC
1
38
GROUND
85 87
30 86
K51
20
DB/YL
42 23
DG/OR
16
A142
RELAY
POWER
DIESEL
OUTPUT
(ST-RUN)
IGN.
FUSED
BK/TN
ST-RUN A21
BS33
JUNCTION
BLOCK
30
C1
F87
18
WT/BK
17
FUSE
20A
POWER
DISTRIBUTION
CENTER
BATT A0
8
C6
5
C6
A142
18
DG/OR
DIESEL
POWER
RELAY
3
DB/YL
20
K51
DIESEL
POWER
RELAY
TO
CENTER
DISTRIBUTION
POWER
A142
16
DG/OR
45
RELAY
POWER
DIESEL
OUTPUT
A142
16
DG/OR
68
RELAY
POWER
DIESEL
OUTPUT
7 E96
B108
1
DG/OR
18
A142
DG/OR
18
A142 A142
18
DG/OR
ES06
WT/BK
18
F87
24
GROUND
Z12
16
BK/TN BK/TN
16
Z12 Z12
16
BK/TN
BS31
G300
7
86
85
(IN PDC)
RELAY
MOTOR
STARTER
ENGINE
6
B107
E95
STARTER
RELAY
CONTROL
3
K90
18
TN
K90
20
TN
(8W-12-13)
(8W-10-16)
(8W-12-2)
(8W-10-25)
(8W-10-9)
(8W-10-8)
(8W-10-27)
(8W-10-25)
(8W-15-3)
(8W-15-5)
(8W-21-3)
DIESEL
NS/GS
J988W-3 GS003028
9A
PTC
1
85 87
30 86
DG/WT
16
A141
ST-RUN A21
30
C1
F87
18
WT/BK
16
FUSE
20A
POWER
DISTRIBUTION
CENTER
BATT A0
3
C6
7
C2
6 C2
1
HEATER
FUEL
FUEL
HEATER
RELAY
4
B33
E120
2
Z1
20
BK
TO
MODULE
CONTROL
POWERTRAIN
BATTERY
Z0
2
BK BK
6
Z0 Z0
10
BK
ES01
G103
G100
ES02
Z1
16
BK
BK
18
Z1
POWERTRAIN
CONTROL
MODULE
K35
20
GY/YL
25
C6
5
20A
FUSE
17
A142
18
DG/OR
30
87
JUNCTION
BLOCK
ES06
CONTROL
SOLENOID
EGR
2
E96
B108
Z1
18
BK
2
1
HEATER
CASE
CRANK
A141
18
DG/WT
A141
18
DG/WT
ES40
1
2
A142
18
DG/OR
K35
20
GY/YL
EGR
SOLENOID
A141
18
DG/WT
F87
18
WT/BK
DIESEL
POWER
RELAY
(8W-12-13)
(8W-10-16)
(8W-10-26)
(8W-10-9)
(8W-10-8)
(8W-30-36)
(8W-20-3)
(8W-15-3)
(8W-15-3)
(8W-10-25)
(8W-12-2)
(8W-30-28)
DIESEL
8W - 30 - 29
GS003029 J988W-3
POWERTRAIN
CONTROL
28
FUSE
10A
POWER
DISTRIBUTION
CENTER
5
C3
BATT A0
13 C1
JUNCTION
BLOCK
17
C4
M1
20
PK
PK
20
M1
16
M1 20 PK
C1 7
B(+)
FUSED
RADIO
PK
20
D21
B23
P18
61
7
D21
20
PK
P34
B23
BK/WT
20
Z11
5 4
Z2
20
BK/LG
G200
1
Z11
20
BK/WT
CONNECTOR
LINK
DATA
MODULE
17
B17
24
A24
TRANSMIT
SCI
1
G301
FUSED
B(+)
16 C1
MODULE
MIRROR
SEAT/
MEMORY
M1 20PK
(8W-10-11)
(8W-10-9)
(8W-10-8)
(8W-12-2)
(8W-47-2)
(8W-15-4) (8W-15-12)
(8W-63-4)
(8W-12-20)
DIESEL
NS/GS
J988W-3 GS003030
TWISTED
PAIR
D2
20
WT/BK
D1
20
VT/BR
TWISTED
PAIR
PAIR
TWISTED
PS02
PS01
VT/BR
20
D1
WT/BK
20
D2
(+)
CCD
BUS
C2 3 4 C2
MODULE
CONTROL
AIRBAG
BUS
CCD
(-)
D2
20
WT/BK
D1
20
VT/BR
10 9
CCD
BUS
(+)
CCD
BUS
(-)
INSTRUMENT
CLUSTER
VT/BR
20
D1
WT/BK
20
D2
VT/BR
20
D1
WT/BK
20
D2
B12
12
VT/BR
D1
18
WT/BK
18
D2
P18
B23
13
B13
CCD
BUS
(+) (-)
BUS
CCD
WT/BK
18
D2 D1
18
VT/BR
(-)
BUS
CCD
(+)
BUS
CCD
19
BS05
20
CONTROLLER
ANTI-LOCK
BRAKE
BODY
CONTROL
MODULE
C2 34 3 C2
BS06
TWISTED
PAIR
6
VT/BR
18
D1
6
CCD
BUS
(+)
OVERHEAD
CONSOLE
(-)
BUS
CCD
1
COMPASS/
MINI-TRIP
COMPUTER
D2
18
WT/BK
5
C20
B75
3 11
CONNECTOR
LINK
DATA
PAIR
TWISTED TWISTED
PAIR
PAIR
TWISTED
TWISTED
PAIR
(8W-43-3)
(8W-40-2)
(8W-35-3)
(8W-45-3)
(8W-49-2)
(8W-49-2)
DIESEL
8W - 30 - 31
GS003031 J988W-3
GY
10
K154
POWER
DISTRIBUTION
CENTER
BATT A0
BATTERY
POWERTRAIN
CONTROL
MODULE
50
C6
5
20A
FUSE
17
A142
18
DG/OR
30
87
ES06
5
E95
B107
WT/DG
18
K152
DG/OR
18
A142
ES29
2 4
1 3
RELAY
PLUG
GLOW
A0
10
RD
ES26
K152
20
WT/DG
CONTROL
RELAY
PLUG
GOW
DB
16
FUSIBLE
LINK
A0
ES28
A54
10
RD
NO. 2
PLUG
GLOW
K154
12
BK BK
12
K154
GLOW
PLUG
NO. 1
BK
12
K154
GLOW
PLUG
NO. 3
BK
12
K154
GLOW
PLUG
NO. 4
ES37
20
G85
OR/BK
26
LAMP
PLUG
GLOW
LAMP/
FAULT
P34
B23
17
A17
OR/BK
G85
20
7
10
CENTER
MESSAGE
PLUG
GLOW
6
FUSE
20A
JUNCTION
BLOCK
BR/PK
18
V23
C4
14
ST-RUN A21
LAMP
DIESEL
POWER
RELAY
C1 10
A/C
HEATER
CONTROL
V23
18
BR/PK
(8W-10-9)
(8W-10-8)
(8W-20-3)
(8W-10-25)
(8W-10-25)
(8W-10-25)
(8W-46-3)
(8W-12-9)
(8W-12-2)
(8W-10-16)
(8W-30-28)
(8W-42-4)
DIESEL
NS/GS
J988W-3 GS003032
POWERTRAIN
CONTROL
MODULE
33
6
E97
B106
GROUND
SENSOR
FUEL
PUMP
7 4
SENSOR
TEMPERATURE
FUEL FUEL
QUANTITY
ACTUATOR
8 6 5
SOLENOID
TIMING
FUEL FUEL
SHUTDOWN
SOLENOID
9 10
POWER
DISTRIBUTION
CENTER
BATT A0
C6
5
20A
FUSE
17
A142
18
DG/OR
30
87
RELAY
POWER
DIESEL
ES06
DG/OR
18
A142 A142
18
DG/OR
K156
18
GY
B108
E96
9
GY
20
K156
63
FUEL
TEMPERATURE
SENSOR
K4
20
BK/LB
BK/LB
20
K4
BS34
ES05
K4
20
BK/LB
8
E96
B108
TN/WT
18
K140
K140
TN/WT
5 4
TN/WT
18
K140
49
TN/WT
K140
BS32
(TWISTED PAIR)
FUEL QUANTITY ACTUATOR
18 18
18
TN/WT
K140
K126
18
LG
B106
E97
1
LG
20
K126
51
CONTROL
SOLENOID
TIMING
SIGNAL
OR/DG
18
K153
E95
B107
4
53
FUEL
SHUTDOWN
SOLENOID
CONTROL
K153
18
OR/DG
MODULE
K4
18
BK/LB
SIGNAL
(8W-10-9)
(8W-10-8)
(8W-10-25)
(8W-10-25)
(8W-70-11)
(8W-70-11)
(8W-30-28)
DIESEL
8W - 30 - 33
GS003033 J988W-3
POWERTRAIN
CONTROL
MODULE
7
2
E95
B107
LG/OR
18
K57
20
PUMP
FUEL
2
CONTROL
SLEEVE
SENSOR
3 1
5 6
K135
18
WT/BK
20
K135
WT/BK
52 29
LB/BK
K134
20
K134
18
LB/BK
K57
LG/OR
(-)
SENSOR
POSITION
SLEEVE CONTROL
SLEEVE
POSITION
SENSOR (+)
SENSOR
POSITION
SLEEVE
MODULE
E96
B108
SLEEVE
POSITION
SENSOR
(+) SENSOR
POSITION
SLEEVE
CONTROL SLEEVE
POSITION
SENSOR
(-)
SUPPLY
5V SENSOR
GROUND
SENSOR
TEMPERATURE
AIR
INTAKE
BK/LB
K4
20
K9
LB
41 64
BK/RD
K21
20
3 2 1
20
B106
E97
6
33
BOOST
PRESSURE
SIGNAL
40
DG/RD
20
K1
4
K4
18
BK/LB
K9
18
LB
ES05
K4
20
BK/LB
K4
18
BK/LB
8 6 7
E120
B33
SENSOR
PRESSURE
BOOST
TURBO
K21
18
BK/RD
K1
18
DG/RD
SIGNAL
PRESSURE
BOOST
INTAKE
AIR
TEMPERATURE
SENSOR GROUND
SENSOR 5V
SUPPLY
BS34
(8W-70-11)
(8W-70-11)
DIESEL
NS/GS
J988W-3 GS003034
POWERTRAIN
CONTROL
MODULE
1 2
12
3
K67
18
BR/BK
K68
18
LG/YL
SENSOR
MOVEMENT
NEEDLE
4
BR/BK
20
K67
11
LG/YL
20
K68
BK/VT
20
K3
GY/BK
20
K24
5
8
1 3
ENGINE
SPEED
SENSOR
E97
B106
21
2
ES31
BK
18
Z122
BK
18
Z122
Z1
18
BK
BS41
G300
7
BS31
Z12
14
BK/TN
Z1
18
BK BK
18
Z1
7
Z122
18
BK
BK
18
Z1
ES30
ENGINE
SPEED
SENSOR
Z122
18
BK
K3
20
BK/VT
K24
18
GY/BK
BS40
6
G301
SHIELD SHIELD
SENSOR
RETURN
ENGINE
SPEED
SENSOR
(+)
SENSOR
MOVEMENT
NEEDLE
Z12 18 BK
NEEDLE
MOVEMENT
SENSOR
(-)
9
E120
B33
(-)
SENSOR
MOVEMENT
NEEDLE NEEDLE
MOVEMENT
SENSOR
(+)
SIGNAL
SPEED
ENGINE
ENGINE
SPEED
SENSOR
RETURN
(8W-15-5)
(8W-15-3)
(8W-15-12)
DIESEL
8W - 30 - 35
GS003035 J988W-3
POWERTRAIN
CONTROL
MODULE
9A
PTC
1
38
(ST-RUN)
IGNITION
FUSED
ST-RUN A21
JUNCTION
BLOCK
30
C1
F87
18
WT/BK
6
6
C6
C2
CENTER
DISTRIBUTION
POWER
F87
18
WT/BK
3
1
SENSOR
SPEED
VEHICLE
2
WT/OR
18
G7
VEHICLE
SPEED
SENSOR
43
4
E96
B108
C1 42
2
K159
20
VT/RD OR/BK
20
G55
59
1
COOLANT
TEMPERATURE
SENSOR
3
60 C1
14
2
33
ES05
GROUND
SENSOR
6
E97
B106
K4
20
BK/LB
BS34
BK/LB
20
K4
8
TN/BK
20
K2
K2
20
TN/BK BK/YL
20
G58
3
E120
B33
G58
20
BK/YL
BODY
CONTROL
MODULE
72
C1
75
C1
BS30
G7
18
WT/OR
WT/OR
18
G7
SENSOR
SPEED
VEHICLE
SENSOR
GROUND
GROUND
SENSOR
K4
20
BK/LB
COOLANT
TEMPERATURE
SENSOR
TEMPERATURE
COOLANT
ENGINE
COOLANT
TEMPERATURE
SENSOR
SIGNAL
SENSOR
TEMPERATURE
(ST-RUN)
IGNITION
FUSED
SENSOR
SPEED
VEHICLE
SIGNAL
SENSOR
SPEED
ENGINE ENGINE
DISABLE
SIGNAL
DISABLE
SIGNAL SENSOR SIGNAL
ENGINE SPEED
F87 18 WT/BK
ENGINE
K4
18
BK/LB
SIGNAL
SIGNAL
COOLANT
SIGNAL SIGNAL
ENGINE
SIGNAL
ENGINE
SENSOR
SIGNAL
(8W-12-13)
(8W-10-16)
(8W-12-2)
(8W-10-29)
(8W-70-11)
(8W-70-11)
(8W-45-9)
DIESEL
NS/GS
J988W-3 GS003036
K4
20
BK/LB
28
POWERTRAIN
CONTROL
MODULE
CONTROL
RELAY
CLUTCH
COMPRESSOR
A/C
C13
20
DB/OR YL
20
C137
48
ST-RUN F87
POWER
DISTRIBUTION
CENTER
86
85
A/C
COMPRESSOR
CLUTCH
RELAY
7
C6
6
RADIATOR
FAN
RELAY
3
SIGNAL
37
SWITCH
A/C
20
DG/LB
A/C
SWITCH
SIGNAL
C1
B23
P18 36
DG/LB
20
C103
B36
A/C
HEATER
CONTROL
9
E97
B106
DB/OR
20
C13
1
E95
B107
NO. 1 NO. 3
RELAY
FAN
RADIATOR
6
ES09
C137
20
YL
YL
20
C137 C137
20
YL
10
LOW SPEED
RADIATOR
FAN RELAY
NO. 2
CONTROL
6
C24
20
DB/PK
NO. 2
RELAY
FAN
RADIATOR
6
DB/PK
20
C24
C103
LOW
SPEED
RADIATOR
FAN
RELAY
CONTROL CONTROL
RELAY
FAN
RADIATOR
SPEED
HIGH
CONTROL
RELAY
RADIATOR
FAN
SPEED
HIGH
CONTROL
NO. 1&3
FAN RELAY
RADIATOR
HIGH SPEED
(8W-10-29)
(8W-10-10)
(8W-42-9)
(8W-42-3)
(8W-42-10) (8W-42-10) (8W-42-10)
DIESEL
8W - 30 - 37
GS003037 J988W-3
POWERTRAIN
CONTROL
MODULE
7
15
OR/DB
K22
20 20
K167
BR/YL
55
8
20
K6
VT/WT
57
10
33
SENSOR
GROUND
TRANSDUCER
PRESSURE
A/C
DB
C18
20 20
K7
OR
1 3
2
ACCELERATOR
PEDAL
13
OUTPUT
5V
19
3
BS34
20
K151
WT
65
5
A/D
PRESSURE
A/C
BK/LB
K4
20
SENSOR
GROUND
LOW
IDLE
POSITION
SWITCH SIGNAL
SENSOR
PEDAL
ACCELERATOR
GROUND
SENSOR
PEDAL
ACCELERATOR
SUPPLY
5V
SWITCH
POSITION
IDLE
LOW ACCELERATOR
PEDAL
SENSOR
SIGNAL
SUPPLY
5V
GROUND
SENSOR
PEDAL
ACCELERATOR
20
K4
BK/LB
20
K4
BK/LB
SENSOR
POSITION
(8W-70-11)
DIESEL
NS/GS
J988W-3 GS003038
POWERTRAIN
CONTROL
MODULE
17
20A
FUSE
13
8
C3
F32
18
PK/DB
K119
20
LG/BK
CENTER
DISTRIBUTION
POWER
BATT A0
2
1
SWITCH
LAMP
STOP
6
Z1
20
BK
FROM
LAMP
SIGNAL
TURN
PARK/
FRONT
LEFT
2
1
CLUTCH
SWITCH
BK
20
Z1
1
G300
Z1
20
BK
FROM
MOTOR
LEVELING
HEADLAMP
LEFT
V37
20
WT
WT
20
V37
CLOCKSPRING
LEFT
SPEED
CONTROL
SWITCH
RIGHT
20
WT/PK
20
K29
BK
18
Z1
6 5
44
STOP
LAMP
SWITCH
SIGNAL SENSE
SWITCH
BRAKE
BS01
CLUTCH
SWITCH
SIGNAL
L50
18
WT/TN
WT/TN
18
L50
LB/RD
20
V38
27
C1 56
P34
B23
A21
21
36
V37
20
RD/LG
SPEED
CONTROL
SWITCH
SIGNAL
RD/LG
20
V37
BODY
CONTROL
MODULE
SWITCH
CONTROL
SPEED
DRIVER
LAMP
CONTROL
SPEED
4
3
4 C2
SPEED
CONTROL
LAMP
DRIVER
(8W-10-29)
(8W-10-10)
(8W-10-8)
(8W-50-11)
(8W-15-7)
(8W-15-8)
(8W-50-8)
(8W-70-2)
(8W-45-9)
(8W-33-4)
(8W-33-4)
(8W-33-4)
(8W-33-5)
DIESEL
8W - 30 - 39
GS003039 J988W-3
8W-31 TRANSMISSION CONTROL SYSTEM
Component Page
Al l Wheel Dri ve Sol enoi d. . . . . . . . . . . . . . . .8W-31-3
AW4 B13 . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-31-3
AWS1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-31-3
AWS2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-31-3
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-31-2
BS02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-31-3
BS05 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-31-8
BS06 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-31-8
Cl utch I nterl ock Swi tch Jumper . . . . . . . . . .8W-31-5
Control l er Anti -Lock Brake . . . . . . . . . . . . . .8W-31-3
Crankshaft Posi ti on Sensor . . . . . . . . . . . . . .8W-31-4
Data Li nk Connector . . . . . . . . . . . . . . . . . . .8W-31-8
ES01 . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-31-2, 6, 7
ES02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-31-4
ES05 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-31-4
ES08 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-31-4
ES10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-31-3, 5
ES11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-31-2
ES13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-31-8
ES14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-31-8
ES21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-31-4
ES24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-31-8
Fuse 2 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . .8W-31-5
Fuse 10 (JB) . . . . . . . . . . . . . . . . . . . . . . . . .8W-31-5
Component Page
Fuse 12 (JB) . . . . . . . . . . . . . . . . . . . . . . . . .8W-31-3
Fuse 15 (PDC) . . . . . . . . . . . . . . . . . . . .8W-31-2, 6, 7
G100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-31-2
G103 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-31-2
G302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-31-3
Juncti on Bl ock . . . . . . . . . . . . . . . . . . . . . .8W-31-3, 5
Low/Reverse Pressure Swi tch . . . . . . . . . . . .8W-31-6
Low/Reverse Sol enoi d . . . . . . . . . . . . . . . . . .8W-31-7
Output Shaft Speed Sensor . . . . . . . . . . . . . .8W-31-3
Overdri ve Pressure Swi tch . . . . . . . . . . . . . .8W-31-6
Overdri ve Sol enoi d . . . . . . . . . . . . . . . . . . . .8W-31-7
Power Di stri buti on Center . . . . . . . . .8W-31-2, 5, 6, 7
Powertrai n Control Modul e . . . . . . . . . .8W-31-4, 5, 6
PS01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-31-8
PS02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-31-8
Throttl e Posi ti on Sensor . . . . . . . . . . . . . . . .8W-31-4
Transmi ssi on Control
Modul e . . . . . . . . . . . . . . . .8W-31-2, 3, 4, 5, 6, 7, 8
Transmi ssi on Control Rel ay. . . . . . . . . .8W-31-2, 6, 7
Transmi ssi on Control Sol enoi ds. . . . . . . . .8W-31-6, 7
Transmi ssi on Range Sensor . . . . . . . . . . . .8W-31-3, 5
Turbi ne Speed Sensor . . . . . . . . . . . . . . . . . .8W-31-3
Underdri ve Sol enoi d . . . . . . . . . . . . . . . . . . .8W-31-7
NS/GS 8W - 31 TRANSMISSION CONTROL SYSTEM 8W - 31 - 1
85 87
30 86
17
TRANSMISSION
CONTROL
MODULE
53
Z14
16
BK/YL BK/RD
16
Z13
57
GROUND GROUND
15
T15
18
LG
12V
SUPPLY
RD
18
T16
16
ES01
20A
FUSE
15
RD/DB
18
A5
10
C8
56
B(+)
FUSED
OUTPUT
RELAY
TRANSMISSION TRANSMISSION
RELAY
OUTPUT
BATTERY
Z0
10
BK
ES11
CENTER
DISTRIBUTION
POWER
BATT A0
C8
3
C8
4
C8
2
TRANSMISSION
CONTROL
RELAY
T16
18
RD RD
18
T16
Z0
8
BK BK
6
Z0
G100 G103
Z16
18
BK
Z16
18
BK
EATX EATX
(8W-10-28)
(8W-10-28)
(8W-20-2)
(8W-15-2)
(8W-10-9)
(8W-10-8)
8W - 31 - 2 8W-31 TRANSMISSION CONTROL SYSTEM NS/GS
J988W-3 GS003102
F20
20
WT
18
C2
10A
FUSE
12
BLOCK
JUNCTION
TRANSMISSION
RANGE
SENSOR
R
E36
B33
5
6
1
L1
18
VT/BK
G302
5
AW4
B13
Z1
14
BK
TRANSMISSION
CONTROL
MODULE
13
DB/BK
18
T13
18
T13
DB/BK
18
T13
ES10
SENSOR
SPEED
SHAFT
OUTPUT TURBINE
SPEED
SENSOR
1 2 1 2
14
T14
18
LG/WT
T52
18
RD/BK
52
SIGNAL
SENSOR
SPEED
SHAFT
OUTPUT
GROUND
SENSOR
SPEED
SIGNAL
SENSOR
SPEED
INPUT
DB/BK
B33
E36
10
BS02
VT/BK
18
L1
RUN A22
2
B13
AW4
1
AWS2
(3.8L)
SOLENOID
DRIVE
WHEEL
ALL
1
2
L1
20
VT/BK
Z1
16
BK
23
CONTROLLER
ANTI-LOCK
BRAKE
F20
18
WT
C2 C1
C1 C2
2
1
F20
18
WT
L1
20
VT/BK
Z1
18
BK BK
18
Z1
AWS1
FUSED
IGNITION
(RUN)
(8W-12-12)
(8W-12-2)
(8W-15-13)
(8W-70-8)
(8W-70-2)
(8W-10-14)
(8W-35-2)
(8W-15-13)
NS/GS 8W-31 TRANSMISSION CONTROL SYSTEM 8W - 31 - 3
GS003103 J988W-3
TRANSMISSION
CONTROL
MODULE
6
K24
18
GY/BK
C1
32
SIGNAL
SENSOR
POSITION
CRANKSHAFT
CRANKSHAFT
POSITION
SENSOR
SIGNAL
GY/BK
18
K24
GY/BK
18
K24
3
CRANKSHAFT
POSITION
SENSOR SENSOR
POSITION
THROTTLE
2
SIGNAL
SENSOR
POSITION
THROTTLE
THROTTLE
POSITION
SENSOR
SIGNAL
35
C1
OR/DB
18
K22
12
K22
18
OR/DB
ES08 ES05
POWERTRAIN
CONTROL
MODULE
GROUND
SENSOR
SENSOR
GROUND
BK/LB
18
K4
K4
18
BK/LB
ES21
SIGNAL
SENSOR
SPEED
VEHICLE
VEHICLE
SPEED
SENSOR
SIGNAL
WT/OR
18
G7
43
C2
51 58
66
C2
OR/DB
18
K22
ES02 ES21
ES02
3.3L/3.8L 2.4L
BK/LB
18
K4 K4
18
BK/LB
CRANKSHAFT
POSITION
SENSOR
SIGNAL
THROTTLE
POSITION
SENSOR
SIGNAL
(8W-30-14)
(8W-30-22)
(8W-30-17)
(8W-30-25)
(8W-30-14)
(8W-30-17)
(8W-30-22)
(8W-30-25)
(8W-70-5)
(8W-70-5) (8W-70-6)
(8W-70-6)
J988W-3 GS003104
MODULE
CONTROL
TRANSMISSION
41
9 8 7 5
PN PRNL P3L NOL
4 3
SENSOR
RANGE
TRANSMISSION
T41
18
BK/WT
T42
18
VT/WT
42 3
VT
18
T3 T1
18
LG/BK
1 54
T54
18
VT/LG
TEMPERATURE
SENSOR
SIGNAL
T13
18
DB/BK
13
GROUND
SENSOR
SPEED
ES10
SENSOR
TEMPERATURE
TRANSMISSION
10
BR/YL
18
T41
SENSE
T1
SWITCH
RANGE
TRANSMISSION
DB/BK
18
T13
TRANSMISSION
RANGE
SWITCH
T3
SENSE
TRANSMISSION
RANGE
SWITCH
T42
SENSE
TRANSMISSION
RANGE
SWITCH
T41
SENSE
76
POWERTRAIN
CONTROL
MODULE
C2
SENSE
T41
SWITCH
RANGE
TRANS.
F45
20
YL/RD
10
C2
10A
FUSE
10
BLOCK
JUNCTION
8
YL/RD
18
F45
ST A41
POWER
DISTRIBUTION
CENTER
7
C8
3 C2
TRANSMISSION
(ST)
IGNITION
FUSED FUSED
IGNITION
(ST-RUN-OFF)
10A
FUSE
2
ST-RUN-OFF A81
C1
20
RD/WT
20
F11
E36
B33
8
F11
18
RD/WT
11
2
1
T141
20
YL/RD
F45
20
YL/RD
JUMPER
SWITCH
INTERLOCK
CLUTCH
D1
(8W-70-8)
(8W-30-19)
(8W-30-27)
(8W-12-16)
(8W-12-2)
(8W-10-16)
(8W-10-16)
(8W-12-9)
(8W-10-16)
GS003105 J988W-3
TRANSMISSION
CONTROL
MODULE
87
30
CENTER
DISTRIBUTION
POWER
4
2 1 3
TRANSMISSION
CONTROL
SOLENOIDS
T16
18
RD
50 47 9
DG
18
T50 T47
18
YL/BK
T9
OR/BK
2-4
PRESSURE
SWITCH
SENSE SENSE
SWITCH
PRESSURE
OVERDRIVE
SENSE
SWITCH
PRESSURE
REVERSE
LOW/
LOW/
REVERSE
PRESSURE
SWITCH
SWITCH
PRESSURE
2-4
SWITCH
PRESSURE
OVERDRIVE
18
ES01
RD
18
T16
20A
FUSE
15
BATT A0
TRANSMISSION
CONTROL
RELAY
2
C8
(8W-10-9)
(8W-10-28)
(8W-10-28)
(8W-10-8)
(8W-31-2)
J988W-3 GS003106
TRANSMISSION
CONTROL
MODULE
8
4
7 5 6
20
CONTROL
SOLENOID
REVERSE
LOW/
T20
18
LB
19
2-4
SOLENOID
CONTROL
59
UNDERDRIVE
SOLENOID
CONTROL
60
OVERDRIVE
SOLENOID
CONTROL
T19
18
WT
T60
18
BR
T59
18
PK
LOW/
REVERSE
SOLENOID
SOLENOID
2-4 UNDERDRIVE
SOLENOID
OVERDRIVE
SOLENOID
SOLENOIDS
CONTROL
TRANSMISSION
87
30
CENTER
DISTRIBUTION
POWER
T16
18
RD
ES01
RD
18
T16
20A
FUSE
15
BATT A0
TRANSMISSION
CONTROL
RELAY
2
C8
(8W-10-9)
(8W-10-28)
(8W-10-28)
(8W-10-8)
(8W-31-2)
GS003107 J988W-3
MODULE
CONTROL
TRANSMISSION
CCD
BUS
(-)
WT/BK
18
D2
4
CCD
BUS
(+)
VT/BR
18
D1
43
SCI
TRANSMIT
MODULE
CONTROL
POWERTRAIN
65
C2 C2
63
T10
18
YL/DG
10
SCI
RECEIVE
46
PK/LB
18
D6
TORQUE
MANAGEMENT
REQUIREMENT
SENSE
SCI
TRANSMIT
7
PK
18
D21
TORQUE
MANAGEMENT
REQUEST
SENSE
D6
20
PK/LB
D21
18
PK
7
14
DATA
LINK
CONNECTOR
ES24
PK
18
D21
D1
20
VT/BR
D2
20
WT/BK
3 11
PS01 PS02
P18
B23
E36
B33 6
D6
20
PK/LB
P18
B23
E36
B33
4
WT/BK
20
D2
VT/BR
20
D1
7 2
ES14 ES13
BS06 BS05
D21
20
PK
B17
17
13
B13
12
B12
14
B14
D1
18
VT/BR
D2
18
WT/BK
PAIR
TWISTED
PAIR
TWISTED
(8W-30-3)
(8W-30-19)
(8W-30-27)
(8W-30-3)
(8W-30-4)
(8W-30-3)
(8W-30-4) (8W-30-4)
(8W-30-4) (8W-30-4)
(8W-30-4) (8W-30-4)
J988W-3 GS003108
8W-33 VEHICLE SPEED CONTROL
Component Page
Accel erator Pedal Posi ti on Sensor . . . . . . . . .8W-33-5
Body Control Modul e. . . . . . . . . . . . . . . . . . .8W-33-4
BS01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-33-5
BS30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-33-4
BS32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-33-5
Cl ockspri ng . . . . . . . . . . . . . . . . . . . . . . . .8W-33-2, 4
Cl utch Swi tch . . . . . . . . . . . . . . . . . . . . . . . .8W-33-5
Dump Sol enoi d . . . . . . . . . . . . . . . . . . . . . . .8W-33-3
ES18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-33-3
Fuel Pump Modul e . . . . . . . . . . . . . . . . . . . .8W-33-5
Fuse 13 (PDC). . . . . . . . . . . . . . . . . . . . . . . .8W-33-5
G101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-33-3
G200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-33-2, 4
Component Page
G300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-33-3, 5
Juncti on Bl ock . . . . . . . . . . . . . . . . . . . . . . . .8W-33-3
Left Headl amp Level i ng Motor . . . . . . . . . . .8W-33-5
Left Speed Control Swi tch . . . . . . . . . . . . .8W-33-2, 4
Power Di stri buti on Center . . . . . . . . . . . . . .8W-33-5
Powertrai n Control Modul e . . . . . . . .8W-33-2, 3, 4, 5
Ri ght Speed Control Swi tch. . . . . . . . . . . .8W-33-2, 4
Stop Lamp Swi tch . . . . . . . . . . . . . . . . . . .8W-33-3, 5
Transmi ssi on Control Modul e . . . . . . . . . . . .8W-33-2
Vacuum Sol enoi d . . . . . . . . . . . . . . . . . . . . . .8W-33-3
Vehi cl e Speed Control Servo . . . . . . . . . . . . .8W-33-3
Vehi cl e Speed Sensor . . . . . . . . . . . . . . . . .8W-33-2, 4
Vent Sol enoi d . . . . . . . . . . . . . . . . . . . . . . . .8W-33-3
NS/GS 8W - 33 VEHICLE SPEED CONTROL 8W - 33 - 1
MODULE
CONTROL
POWERTRAIN
CLOCKSPRING
41
C2
V37
18
RD/LG
SWITCH
CONTROL
SPEED
LEFT
2 1 1 2
RIGHT
SPEED
CONTROL
SWITCH
3
SPEED
CONTROL
SWITCH
SIGNAL
CLOCKSPRING
4
3
G200
3
Z2
20
BK/LG
V37
20
WT
WT
20
V37
B70
E43
8
B23
P34
A21
RD/LG
20
V37
Z2
20
BK
SIGNAL
SENSOR
SPEED
VEHICLE
WT/OR
18
G7
C2
66
EATX MTX
G7
18
WT/OR WT/OR
18
G7
58 3
VEHICLE
SPEED
SENSOR
TRANSMISSION
CONTROL
MODULE
V37 22 WT
Z2 22 BK
2 CANCEL
1 RESUME/ACCEL
3 COAST
1 SET
2 ON/OFF
21
C2
C2
SIGNAL
SENSOR
SPEED
VEHICLE VEHICLE
SPEED
SENSOR
SIGNAL
(8W-30-11)
(8W-30-17)
(8W-30-25)
(8W-15-4)
(8W-30-11) (8W-31-4)
8W - 33 - 2 8W-33 VEHICLE SPEED CONTROL
GAS
NS/GS
J988W-3 GS003302
56
C2
80
C2
CONTROL
SOLENOID
VACUUM
CONTROL
SPEED SPEED
CONTROL
VENT
SOLENOID
CONTROL
4
1 2
V36
18
TN/RD
V35
18
LG/RD
SERVO
CONTROL
SPEED
VEHICLE
Z1
18
BK
Z1
10
BK
ES18
G101
STOP
LAMP
SWITCH
4
SPEED
CONTROL
ON/OFF
SWITCH
POWERTRAIN
CONTROL
MODULE
C1
5
DB/RD
20
V30
3
VACUUM
SOLENOID
SOLENOID
DUMP
SOLENOID
VENT
3
62
C2
SENSE
SWITCH
LAMP
STOP
YL/RD
18
V32
YL/RD
20
V32
E43
B70 3
6
B70
E43
V30
18
DB/RD
7
K29
18
WT/PK
1
Z1
20
BK
2
WT/PK
20
K29
G300
6
RHD LHD
JUNCTION
BLOCK
TO
5
6
SENSE
(8W-15-2)
(8W-15-2)
(8W-30-13)
(8W-30-19)
(8W-30-27)
(8W-15-7)
(8W-12-19)
NS/GS 8W-33 VEHICLE SPEED CONTROL
GAS
8W - 33 - 3
GS003303 J988W-3
MODULE
CONTROL
POWERTRAIN
CLOCKSPRING
36
V37
20
RD/LG
SWITCH
CONTROL
SPEED
LEFT
2 1 1 2
RIGHT
SPEED
CONTROL
SWITCH
3
SPEED
CONTROL
SWITCH
SIGNAL
CLOCKSPRING
4
3
G200
3
Z2
20
BK/LG
V37
20
WT
21
BK
20
Z2
Z2
22
BK
DRIVER
LAMP
CONTROL
LB/RD
20
V38
27
56
BODY
CONTROL
MODULE
A21
V37
20
RD/LG
WT
22
V37
C1
SPEED
CONTROL
LAMP
43
VEHICLE
SPEED
SENSOR
SENSOR
SPEED
VEHICLE
C1 42
SIGNAL
G7
WT/OR
18
BS30
G7
18
WT/OR
G7
18
WT/OR
4
B108
E96
G7
18
WT/OR
3
VEHICLE
SPEED
SENSOR
SIGNAL
VEHICLE
SPEED
SENSOR
DRIVER
SPEED
1 RESUME/ACCEL
2 CANCEL
3 COAST
1 SET
2 ON/OFF
B23
P34
C2
C2
SIGNAL
(8W-30-36)
(8W-30-39)
(8W-15-4)
(8W-45-9)
(8W-30-36)
8W - 33 - 4 8W-33 VEHICLE SPEED CONTROL
DIESEL
NS/GS
J988W-3 GS003304
BK
20
Z1
LEFT
HEADLAMP
LEVELING
MOTOR
1
1
Z1
20
BK
17
CLUTCH
SWITCH
SIGNAL
20
LG/BK
K119
SWITCH
CLUTCH
1
2
10 7 8
55 15 57
5V
SUPPLY
GROUND
ACCELERATOR
PEDAL
SENSOR SENSOR
PEDAL
ACCELERATOR
SIGNAL
8
TN/WT
18
K140
E96
B108
8
TN/WT
18
K140
BS32
K140
TN/WT
18
K140
TN/WT
18 18
TN/WT
K140
49
FUEL QUANTITY ACTUATOR SIGNAL
5 4
BK
20
Z1
G300
6
BS01
WT/TN
18
L50
18
WT/TN
L50 K29
WT/PK
20
CENTER
DISTRIBUTION
POWER
PK/DB
18
F32
BATT A0
13
FUSE
20A
8
C3
SENSE
SWITCH
BRAKE
20 44
STOP
LAMP
SWITCH
SIGNAL
6
STOP
LAMP
SWITCH
2
1 5
K167
BR/YL
20 20
OR/DB
K22 K6
VT/WT
20
ACCELERATOR
PEDAL
POSITION
SENSOR
MODULE
CONTROL
POWERTRAIN
PAIR
TWISTED TWISTED
PAIR
FUEL
PUMP
MODULE
3
4
ACCELERATOR
PEDAL
SENSOR
SIGNAL
5V
SUPPLY
ACCELERATOR
PEDAL
SENSOR
GROUND
GROUND
FUEL
QUANTITY
ACCUATOR
SIGNAL
(8W-50-8)
(8W-15-7)
(8W-15-8)
(8W-70-2)
(8W-10-10)
(8W-10-8)
(8W-10-29)
(8W-30-38)
(8W-30-33)
(8W-30-38)
(8W-30-39)
(8W-30-33)
NS/GS 8W-33 VEHICLE SPEED CONTROL
DIESEL
8W - 33 - 5
GS003305 J988W-3
8W-35 ANTI-LOCK BRAKES
Component Page
ABS Warni ng Lamp . . . . . . . . . . . . . . . . . . .8W-35-3
Body Control Modul e. . . . . . . . . . . . . . . . .8W-35-2, 3
BS01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-35-3
BS05 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-35-3
BS06 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-35-3
Control l er Anti -Lock Brake . . . . . . . . . .8W-35-2, 3, 4
Fuse 6 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . .8W-35-3
Fuse 12 (JB) . . . . . . . . . . . . . . . . . . . . . . . . .8W-35-2
Fuse 12 (PDC). . . . . . . . . . . . . . . . . . . . . . . .8W-35-2
Fuse 13 (PDC). . . . . . . . . . . . . . . . . . . . . . . .8W-35-3
Fuse 25 (PDC). . . . . . . . . . . . . . . . . . . . . . . .8W-35-2
G104 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-35-2
Component Page
G300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-35-2
Juncti on Bl ock . . . . . . . . . . . . . . . . . . . . . .8W-35-2, 3
Left Front Wheel Speed Sensor . . . . . . . . . . .8W-35-4
Left Rear Wheel Speed Sensor . . . . . . . . . . .8W-35-4
Message Center . . . . . . . . . . . . . . . . . . . . . . .8W-35-3
Power Mi rror Swi tch . . . . . . . . . . . . . . . . . . .8W-35-2
PS01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-35-3
PS02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-35-3
Ri ght Front Wheel Speed Sensor . . . . . . . . . .8W-35-4
Ri ght Rear Wheel Speed Sensor . . . . . . . . . .8W-35-4
Stop Lamp Swi tch . . . . . . . . . . . . . . . . . . . . .8W-35-3
Tracti on Control Swi tch. . . . . . . . . . . . . . . . .8W-35-2
NS/GS 8W - 35 ANTI-LOCK BRAKES 8W - 35 - 1
B (+)
FUSED
9
A20
12
RD/DB
BK
12
Z7
G104
8
GROUND
CONTROLLER
ANTI-LOCK
BRAKE
12
FUSE
25A
POWER
DISTRIBUTION
CENTER
BATT A0
6
C3 C4
6
40A
FUSE
25
RD/DG
12
A10
25
FUSED
B (+)
RUN A22
12
FUSE
10A
JUNCTION
BLOCK
WT
18
F20
C2
18
23
(RUN)
FUSED IGNITION
24
Z7
12
BK
GROUND
22
TRACTION
CONTROL
SWITCH
P34
B23
B27
18
RD/YL
1
2 3
SWITCH
CONTROL
TRACTION
35
G300
8
2
C2
C4
JUNCTION
BLOCK
Z1
14
BK
Z1
20
BK
RD/YL
20
B27
30
C4
E2
20
OR
2
PANEL
LAMPS
DRIVER
11
POWER
MIRROR
SWITCH
BK
20
Z1
BODY
CONTROL
MODULE
A1
1
(GAS) GROUND
SENSE
(8W-10-29)
(8W-10-8)
(8W-10-10)
(8W-10-8)
(8W-10-15)
(8W-10-14)
(8W-12-12)
(8W-12-2)
(8W-15-6)
(8W-12-2)
(8W-62-2)
(8W-62-4)
(8W-62-5)
(8W-45-5)
(8W-12-23)
(8W-12-19)
8W - 35 - 2 8W-35 ANTI-LOCK BRAKES NS/GS
J988W-3 GS003502
CONTROLLER
ANTI-LOCK
BRAKE
STOP
LAMP
SWITCH
SENSE
12
13
FUSE
20A
POWER
DISTRIBUTION
CENTER
8
C3
BATT A0
F32
18
PK/DB
6
5
STOP
LAMP
SWITCH
BS01
L50
18
WT/TN
WT/TN
18
L50
6
FUSE
20A
JUNCTION
BLOCK
BR/PK
18
V23
C4
14
ST-RUN A21
5
10
CENTER
MESSAGE
ABS
WARNING
LAMP
16
P34
B23
G19
20
LG/OR
LG/OR
18
G19
C2
17
BODY
CONTROL
MODULE
ABS
WARNING
LAMP
DRIVER
LG/OR
20
G19
D2
18
WT/BK
CCD
BUS
19
D1
18
VT/BR
20
PS02 PS01
(-) (+)
BUS
CCD
11 3
VT/BR
20
D1
WT/BK
20
D2
3
A3
DATA
LINK
CONNECTOR
PAIR
TWISTED
TWISTED
PAIR
DRIVER
LAMP
WARNING
ABS
*2
* RHD
BS06 BS05
B13
P18 13 12
B12 B23
D2
20
WT/BK
D1
20
VT/BR
D1
18
VT/BR
D2
18
WT/BK
(8W-10-29)
(8W-10-10)
(8W-10-8)
(8W-33-5)
(8W-51-7)
(8W-70-2)
(8W-12-9)
(8W-12-2)
(8W-10-16)
(8W-46-2)
(8W-30-4)
(8W-30-31)
(8W-30-4)
(8W-30-31)
(8W-45-6)
(8W-30-4)
(8W-30-31)
(8W-30-4)
(8W-30-31)
(8W-30-4)
(8W-30-31)
NS/GS 8W-35 ANTI-LOCK BRAKES 8W - 35 - 3
GS003503 J988W-3
CONTROLLER
ANTI-LOCK
BRAKE
LEFT
FRONT
WHEEL
SPEED
SENSOR
LEFT
FRONT
WHEEL
SPEED
SENSOR
(-) (+)
SENSOR
SPEED
WHEEL
FRONT
LEFT
4
2 1 2 1
2 10
2 1
18
RIGHT
FRONT
WHEEL
SPEED
SENSOR
(-) (+)
SENSOR
SPEED
WHEEL
FRONT
RIGHT
3
SENSOR
SPEED
WHEEL
FRONT
RIGHT
B9
18
RD RD/DB
18
B8
WT/DB
18
B6
WT
18
B7
18 18
11
B4
LG
B3
LG/DB
LEFT
REAR
WHEEL
SPEED
SENSOR
(+) (-)
SENSOR
SPEED
WHEEL
REAR
LEFT
LEFT
REAR
WHEEL
SPEED
SENSOR
RIGHT
REAR
WHEEL
SPEED
SENSOR
1 2
RIGHT
REAR
WHEEL
SPEED
SENSOR
(-) (+)
SENSOR
SPEED
WHEEL
REAR
RIGHT
YL/DB
B1
YL
B2
18 18
17 1
8W - 35 - 4 8W-35 ANTI-LOCK BRAKES NS/GS
J988W-3 GS003504
8W-39 VEHICLE THEFT SECURITY SYSTEM
Component Page
Body Control Modul e . . . . . . . . . . . . . . .8W-39-2, 3, 4
BS19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-39-2
Cl ockspri ng . . . . . . . . . . . . . . . . . . . . . . . . . .8W-39-2
Dri ver Door Ajar Swi tch . . . . . . . . . . . . . . . .8W-39-2
Dri ver Door Arm/Di sarm Swi tch . . . . . . . . . .8W-39-3
Dri ver Door Lock Swi tch . . . . . . . . . . . . . . . .8W-39-3
Fuse 9 (PDC). . . . . . . . . . . . . . . . . . . . . . . . .8W-39-2
Fuse 18 (PDC). . . . . . . . . . . . . . . . . . . . . . . .8W-39-5
Fuse 28 (PDC). . . . . . . . . . . . . . . . . . . . . . . .8W-39-2
G200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-39-5
G301 . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-39-2, 3, 4
G302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-39-4
G400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-39-3, 4
Hi gh Note Horn. . . . . . . . . . . . . . . . . . . . . . .8W-39-2
Hood Ajar Swi tch . . . . . . . . . . . . . . . . . . . . .8W-39-4
Horn Rel ay . . . . . . . . . . . . . . . . . . . . . . . . . .8W-39-2
Horn Swi tch . . . . . . . . . . . . . . . . . . . . . . . . .8W-39-2
Juncti on Bl ock . . . . . . . . . . . . . . . . . . . . . .8W-39-2, 5
Component Page
Left Rear Door Ajar Swi tch . . . . . . . . . . . . . .8W-39-4
Li ftgate Ajar Swi tch . . . . . . . . . . . . . . . . . . .8W-39-4
Li ftgate Arm/Di sarm Swi tch . . . . . . . . . . . . .8W-39-3
Low Note Horn . . . . . . . . . . . . . . . . . . . . . . .8W-39-2
Memory Seat/Mi rror Modul e . . . . . . . . . . . . .8W-39-2
Message Center . . . . . . . . . . . . . . . . . . . . . . .8W-39-2
Passenger Door Ajar Swi tch . . . . . . . . . . . . .8W-39-2
Passenger Door Arm/Di sarm Swi tch . . . . . . .8W-39-3
Passenger Door Lock Swi tch . . . . . . . . . . . . .8W-39-3
PS01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-39-5
PS02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-39-5
PTC 1 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . .8W-39-5
Remote Keyl ess Entry Modul e . . . . . . . . . . .8W-39-2
Ri ght Rear Door Ajar Swi tch . . . . . . . . . . . . .8W-39-4
Sentry Key I mmobi l i zer Modul e . . . . . . . . . .8W-39-5
VTSS Lamp . . . . . . . . . . . . . . . . . . . . . . . . . .8W-39-2
NS/GS 8W - 39 VEHICLE THEFT SECURITY SYSTEM 8W - 39 - 1
85 87
30 86
RELAY
HORN
C2
4 8
C2
20A
FUSE
9
BATT A0
POWER
DISTRIBUTION
CENTER
13
12
VTSS
LAMP
CENTER
MESSAGE
28
FUSE
10A
C3
5
JUNCTION
BLOCK
6
C4
13 C1
C2
16
9
BODY
CONTROL
MODULE
VTSS
LAMP
DRIVER
FUSED
B (+) RELAY
HORN
18
CONTROL
M1
20
PK
G69
22
BK/OR
M1
20
PK
C1
16
MODULE
MIRROR
SEAT/
MEMORY
M1
20
PK
C2 4
GY/OR
20
X4
79
C1 C1
48
SENSE
SWITCH
AJAR
DRIVER
DOOR DOOR
PASSENGER
AJAR
SWITCH
SENSE
DRIVER
DOOR
AJAR
SWITCH
SWITCH
AJAR
DOOR
PASSENGER
G75
18
TN
G74
18
TN/RD
HORN
NOTE
LOW HIGH
NOTE
HORN
X2
18
DG/RD
X2
18
DG/RD
X2
18
DG/RD
BS19
A A
B B
Z1
18
BK
Z1
18
BK
G301
FUSED
B (+)
1 13
HORN
SWITCH
CLOCKSPRING
X3
20
BK/RD
20
C2
1
X3
20
BK/RD
CONTROL
RELAY
HORN
*7
*8
* RHD
C2
3
MODULE
ENTRY
KEYLESS
REMOTE
7 P50
NOT
USED
M1
20
PK
M1
22
PK
(8W-10-30)
(8W-10-8)
(8W-10-9)
(8W-10-10)
(8W-46-2)
(8W-10-11)
(8W-12-2)
(8W-45-3)
(8W-45-7)
(8W-62-3)
(8W-63-4)
(8W-15-10)
(8W-15-11)
(8W-41-2) (8W-41-2)
(8W-61-5)
(8W-12-20)
8W - 39 - 2 8W-39 VEHICLE THEFT SECURITY SYSTEM NS/GS
J988W-3 GS003902
BK/LG
20
Z2
9
G400
WT/RD
20
P98
6
J03A
L16
LJ01
B17
6
WT/RD
20
P98
C1
44
SIGNAL
MUX
LIFTGATE
BK/LG
20
Z2
BK/LG
20
Z2
Z2
20
BK/LG
2
SWITCH
LOCK
DOOR
PASSENGER
3
B03
D01P
3
Z2
20
BK/LG
55
C1
P96
20
WT/LG
4
B03
D01P
P96
20
WT/LG
P96
20
WT/LG
BK/LG
20
Z2
3
D01D
B02
BK/LG
20
Z2
G301
WT/DG
20
P97
3
DRIVER
DOOR
LOCK
SWITCH
2
WT/DG
20
P97
D01D
B02
11
WT/DG
18
P97
DRIVER
BODY
CONTROL
MODULE
C1
45
DOOR
SWITCH
MUX
SWITCH
DISARM
ARM/
LIFTGATE
1
2
2 1
1 2
2
1
PASSENGER
DOOR
ARM/
DISARM
SWITCH SWITCH
DISARM
ARM/
DOOR
DRIVER
1
2
2 1
2 3
1 UNLOCK
2 LOCK 2 LOCK
1 UNLOCK
2 LOCK
1 UNLOCK
PASSANGER
DOOR
SWITCH
MUX
MUX
SWITCH
DOOR
DRIVER PASSANGER
DOOR
SWITCH
MUX
GROUND
(8W-15-14)
(8W-61-6)
(8W-15-10)
(8W-15-11)
(8W-61-6)
(8W-45-6)
(8W-45-8)
NS/GS 8W-39 VEHICLE THEFT SECURITY SYSTEM 8W - 39 - 3
GS003903 J988W-3
TN/BK
18
G78
BK
20
Z1
G400
SWITCH
AJAR
LIFTGATE
3
1
Z1
18
BK
G301
G70
18
BR/TN
C1
43
SENSE
SWITCH
AJAR
HOOD
L16
J03A
4
TN/BK
18
G78
4
B17
LJ01
SENSE
SWITCH
AJAR
LIFTGATE
59
C1
TN/BK
18
G78
G302
BK
18
Z1
BK
18
Z1
REAR
RIGHT
C1
77
DOOR
AJAR
SWITCH
SENSE
G76
18
TN/YL TN/OR
18
G77
2
SWITCH
AJAR
HOOD
1 2
RIGHT
REAR
DOOR
AJAR
SWITCH
1 1
SWITCH
AJAR
DOOR
REAR
LEFT
2
SENSE
SWITCH
AJAR
DOOR
47
C1
MODULE
CONTROL
BODY
LEFT
REAR
8 14 12 11
(8W-15-14) (8W-15-10) (8W-15-13)
(8W-45-7)
(8W-45-8)
8W - 39 - 4 8W-39 VEHICLE THEFT SECURITY SYSTEM NS/GS
J988W-3 GS003904
18
FUSE
15A
BATT A0
12
CENTER
DISTRIBUTION
POWER
2
C2
15 C2
F41
20
PK/VT
20
C3
PTC
1
9A
ST-RUN A21
BLOCK
JUNCTION
C4
19
MODULE
IMMOBILIZER
KEY
SENTRY
1
F41
20
PK/VT
3
F87
20
WT/BK
FUSED
B(+)
FUSED
IGNITION
(ST-RUN)
CCD
BUS
(+) (-)
BUS
CCD
GROUND
Z2
20
BK
G200
2 5 6
D1
20
VT/BR
D2
20
WT/BK
TO
PS01
TO
PS02
(8W-10-20)
(8W-10-8)
(8W-10-9)
(8W-12-13)
(8W-10-16)
(8W-12-2)
(8W-15-4)
(8W-30-4) (8W-30-4)
NS/GS 8W-39 VEHICLE THEFT SECURITY SYSTEM
BUILT-UP-EXPORT
8W - 39 - 5
GS003905 J988W-3
8W-40 INSTRUMENT CLUSTER
Component Page
A/C Heater Control . . . . . . . . . . . . . . . . . . . .8W-40-4
AW4 B13 . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-40-2
Body Control
Modul e . . . . . . . .8W-40-2, 3, 4, 5, 6, 7, 8, 9, 10, 11
BS05 . . . . . . . . . . . . . . . . . . . . . . . .8W-40-5, 6, 8, 10
BS06 . . . . . . . . . . . . . . . . . . . . . . . .8W-40-5, 6, 8, 10
BS30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-40-7
BS40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-40-7
Cl ockspri ng . . . . . . . . . . . . . . . . . . . . . .8W-40-10, 11
Cl uster I l l umi nati on Lamps . . . . . . . . . . . . .8W-40-4
Crui se I ndi cator Lamp . . . . . . . . . . . . . .8W-40-10, 11
Door Ajar I ndi cator Lamp . . . . . . . . . . . . . . .8W-40-3
El ectroni c PRNDL I ndi cator . . . . . . . . . . . . .8W-40-5
Engi ne Cool ant Temperature Gauge . . . . .8W-40-8, 9
Engi ne Cool ant Temperature Sensor . . . . .8W-40-8, 9
Engi ne Speed Sensor . . . . . . . . . . . . . . . . . . .8W-40-7
ES13 . . . . . . . . . . . . . . . . . . . . . . . .8W-40-5, 6, 8, 10
ES14 . . . . . . . . . . . . . . . . . . . . . . . .8W-40-5, 6, 8, 10
ES30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-40-7
Fuel Gauge . . . . . . . . . . . . . . . . . . . . . . . . . .8W-40-2
Fuel Tank Modul e . . . . . . . . . . . . . . . . . . . . .8W-40-2
Fuse 2 (JB). . . . . . . . . . . . . .8W-40-2, 3, 4, 5, 6, 8, 10
Fuse 28 (PDC). . . . . . . . . . . . . . . . . . . . . . . .8W-40-2
G200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-40-2
G300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-40-4
G301 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-40-7
G302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-40-3
G400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-40-3
Component Page
I gni ti on Swi tch . . . . . . . . . . . . . . . . . . . . .8W-40-2, 4
I nstrument Cl uster . . . . . . . . . . . .8W-40-2, 3, 4, 5, 6,
7, 8, 9, 10, 11
Juncti on Bl ock . . . . . . . . . . .8W-40-2, 3, 4, 5, 6, 8, 10
Left Speed Control Swi tch . . . . . . . . . . .8W-40-10, 11
Li ftgate Ajar I ndi cator Lamp. . . . . . . . . . . . .8W-40-3
Low Fuel Warni ng I ndi cator Lamp . . . . . . . .8W-40-2
Low Washer Fl ui d Level
I ndi cator Lamp . . . . . . . . . . . . . . . . .8W-40-10, 11
Low Washer Fl ui d Swi tch . . . . . . . . . . .8W-40-10, 11
Odometer . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-40-5
Powertrai n Control
Modul e . . . . . . . . . . . . . .8W-40-5, 6, 7, 8, 9, 10, 11
PS01 . . . . . . . . . . . .8W-40-2, 3, 4, 5, 6, 7, 8, 9, 10, 11
PS02 . . . . . . . . . . . .8W-40-2, 3, 4, 5, 6, 7, 8, 9, 10, 11
Ri ght Speed Control Swi tch . . . . . . . . . .8W-40-10, 11
Seat Bel t I ndi cator Lamp . . . . . . . . . . . . . . .8W-40-4
Seat Bel t Swi tch . . . . . . . . . . . . . . . . . . . . . .8W-40-4
Speedometer . . . . . . . . . . . . . . . . . . . . . . .8W-40-6, 7
Tachometer . . . . . . . . . . . . . . . . . . . . . . . .8W-40-6, 7
Transmi ssi on Control Modul e . . . . . . . . . .8W-40-5, 6
Tri p Odometer . . . . . . . . . . . . . . . . . . . . . . . .8W-40-5
Vehi cl e Speed Sensor . . . . . . . . . . . . . . . . .8W-40-6, 7
Vol tage I ndi cator Lamp . . . . . . . . . . . . . . .8W-40-8, 9
NS/GS 8W - 40 INSTRUMENT CLUSTER 8W - 40 - 1
CONTROL
GAUGE
FUEL
GROUND
JUNCTION
BLOCK
28
FUSE
10A
C3
5
BATT A0
PK
20
M1
C1 13
POWER
DISTRIBUTION
CENTER
ST-RUN-OFF A81
10A
FUSE
2
MODULE
MIRROR
SEAT/
MEMORY
CLUSTER
INSTRUMENT
10
C4
11
(ST-RUN-OFF)
IGNITION
FUSED
C4
13
F11
20
RD/WT
PK
20
M1
2
FUSED
B (+)
IGNITION
SWITCH
TO
7
G200
2
Z2
20
BK/LG
FUEL
WARNING
LAMP
CONTROL
FUEL
GAUGE
LOW
FUEL
WARNING
INDICATOR
LAMP
JUNCTION
BLOCK
C1 16
FUSED
B (+)
M1
20
PK
LEVEL
FUEL
46 C1
BODY
CONTROL
MODULE
SENSOR
SIGNAL
LOW
CCD
BUS
(+) (-)
BUS
CCD
9 10
3
FUEL
TANK
MODULE
FUEL
LEVEL
SENSOR
SIGNAL
B13
AW4
3
G4
18
DB
G4
18
DB
WT/BK
20
D2 D1
20
VT/BR
(+)
C2 3
CCD
BUS
(-)
C2 34
CCD
BUS
PS01 PS02
M1
20
PK
PAIR
TWISTED
D1
4 P50
NOT
USED
F11
20
RD/WT
(8W-12-2)
(8W-10-11)
(8W-10-8)
(8W-10-9)
(8W-10-16)
(8W-12-9)
(8W-62-3)
(8W-63-4)
(8W-10-14)
(8W-15-4)
(8W-12-2)
(8W-45-3)
(8W-45-9)
(8W-30-6)
(8W-30-20)
(8W-45-9)
(8W-30-4)
(8W-30-31)
(8W-30-4)
(8W-30-31)
(8W-12-20)
8W - 40 - 2 8W-40 INSTRUMENT CLUSTER NS/GS
J988W-3 GS004002
TN/BK
18
G78
4
J03A
L16
4
B17
LJ01
TN/BK
18
G78
TN/BK
18
G78
BK
20
Z1
SENSE
SWITCH
AJAR
LIFTGATE
C1 59
1
SWITCH
AJAR
LIFTGATE
3
11
G400
2
1
SWITCH
AJAR
DOOR
REAR
RIGHT
RIGHT
REAR
DOOR
AJAR
SWITCH
SENSE
77
C1
G76
18
TN/YL
Z1
18
BK BK
18
Z1
TN/OR
18
G77
C1
47
SENSE
SWITCH
AJAR
DOOR
REAR
LEFT
LEFT
REAR
DOOR
AJAR
SWITCH
1
2
14
G302
8
PASSENGER
DOOR
AJAR
SWITCH
SENSE
48
C1
PASSENGER
DOOR
AJAR
SWITCH
G74
18
TN/RD
TN
18
G75
C1
79
SENSE
SWITCH
AJAR
DOOR
DRIVER
CONTROL
LAMP
AJAR
LIFTGATE
AJAR
INDICATOR
CONTROL
LAMP
INDICATOR
LAMP
AJAR
DOOR
DOOR
AJAR
INDICATOR
PS02 PS01
CCD
BUS
(-) (+)
BUS
CCD
BUS
CCD
34 C2
(-)
BUS
CCD
3 C2
(+)
VT/BR
20
D1 D2
20
WT/BK
10 9
MODULE
CONTROL
BODY
RD/WT
20
F11
FUSED
IGNITION
(ST-RUN-OFF)
11
C4
10
INSTRUMENT
CLUSTER
2
FUSE
10A
ST-RUN-OFF A81
BLOCK
JUNCTION
LIFTGATE
INDICATOR
LAMP
PAIR
TWISTED
SWITCH
AJAR
DOOR
DRIVER
D1
4 P50
F11
20
RD/WT
NOT
USED
(8W-15-14) (8W-15-13)
(8W-30-4) (8W-30-4)
(8W-45-3)
(8W-12-9)
(8W-10-16)
(8W-12-2)
NS/GS 8W-40 INSTRUMENT CLUSTER 8W - 40 - 3
GS004003 J988W-3
1
LG/RD
18
G10
C1
78
SENSE
SWITCH
BELT
SEAT
SWITCH
BELT
SEAT
1
VT/BR
20
D1
WT/BK
20
D2
BK
20
Z1
IGNITION
SWITCH
2
BK
20
Z1
BK
14
Z1
8
G300
C2
2
LAMPS
ILLUMINATION
CLUSTER
C4 28
13
2
BLOCK
JUNCTION
OR
20
E2
6
LAMPS
PANEL
8 C4
DRIVER
WT/BK
20
D2
(-)
C2 34
CCD
BUS
PS02
D1
20
VT/BR
(+)
C2 3
CCD
BUS
PS01
JUNCTION
BLOCK
ST-RUN-OFF A81
10A
FUSE
2
CLUSTER
INSTRUMENT
10
C4
11
(ST-RUN-OFF)
IGNITION
FUSED
F11
20
RD/WT
9 10
CCD
BUS
(+) (-)
BUS
CCD
LAMP
LAMP
CONTROL
INDICATOR
BELT
BELT
INDICATOR
BODY
CONTROL
MODULE
GROUND
2
Z1
20
BK
FROM
CONTROL
A/C
E2
20
OR
C2
SEAT
SEAT
HEATER
PAIR
TWISTED
D1
(8W-10-14)
(8W-15-6)
(8W-15-8)
(8W-12-2)
(8W-30-4)
(8W-30-31)
(8W-30-4)
(8W-30-31)
(8W-12-2)
(8W-10-16)
(8W-12-9)
(8W-45-3)
(8W-45-5)
(8W-45-7)
(8W-42-3)
(8W-12-19)
(8W-12-23)
8W - 40 - 4 8W-40 INSTRUMENT CLUSTER NS/GS
J988W-3 GS004004
JUNCTION
BLOCK
ST-RUN-OFF A81
10A
FUSE
2
10
C4
11
F11
20
RD/WT
D1
18
VT/BR
ES13
D2
18
WT/BK
TRANSMISSION
CONTROL
MODULE
CONTROL
PRNDL
ELECTRONIC
ODOMETER
CONTROL
INDICATOR
PRNDL
ELECTRONIC ODOMETER
ODOMETER
TRIP
WT/BK
18
D2
VT/BR
18
D1
WT/BR
20
D2
VT/BR
20
D1
2 B33
E36
BS06
B23
P18 13
VT/BR
18
D1
7
BS05
12
BUS
CCD
59 C2
(+)
BUS
CCD
60 C2
(-)
D2
18
WT/BK
MODULE
CONTROL
POWERTRAIN
BODY
CONTROL
MODULE
CONTROL
ODOMETER
TRIP
VT/BR
20
D1
WT/BK
20
D2
WT/BK
20
D2
(-)
C2 34
CCD
BUS
PS02
D1
20
VT/BR
(+)
C2 3
CCD
BUS
PS01
9 10
CCD
BUS
(+) (-)
BUS
CCD
(ST-RUN-OFF)
IGNITION
CLUSTER
INSTRUMENT
FUSED
(EATX)
ES14
(EATX)
B13 B12
PAIR
TWISTED TWISTED
PAIR
43 4
(+)
BUS
CCD
BUS
CCD
(-)
TWISTED
PAIR
D1
(8W-12-2)
(8W-10-16)
(8W-12-9)
(8W-31-8)
(8W-30-4)
(8W-30-31)
(8W-30-4)
(8W-30-31)
(8W-30-4)
(8W-45-3)
(8W-30-4)
(8W-30-31)
(8W-30-4)
(8W-30-31)
NS/GS 8W-40 INSTRUMENT CLUSTER 8W - 40 - 5
GS004005 J988W-3
58
TRANSMISSION
CONTROL
MODULE
SIGNAL
SENSOR
SPEED
VEHICLE
G7
18
WT/OR
MTX EATX
WT/OR
18
G7
VEHICLE
SPEED
SENSOR
SIGNAL
SENSOR
SPEED
VEHICLE
3
SIGNAL
VT/BR
18
D1
WT/BK
18
D2
ES14 ES13
E36
7
2 B33
BS06 BS05
B23
P18 13 12
WT/OR
18
G7
SENSOR
C2 66
VEHICLE
SPEED BUS
CCD
60 C2
(-)
BUS
CCD
59 C2
(+)
D1
18
VT/BR
D2
18
WT/BK
POWERTRAIN
CONTROL
MODULE
WT/BK
20
D2
VT/BR
20
D1
BODY
CONTROL
MODULE
9 10
WT/BK
20
D2 D1
20
VT/BR
(+)
C2 3
CCD
BUS
(-)
C2 34
CCD
BUS
PS01
PS02
CCD
BUS
(+) (-)
BUS
CCD
TACHOMETER
CONTROL
TACHOMETER
CONTROL
SPEEDOMETER
SPEEDOMETER
JUNCTION
BLOCK
ST-RUN-OFF A81
10A
FUSE
2
CLUSTER
INSTRUMENT
10
C4
11
(ST-RUN-OFF)
IGNITION
FUSED
F11
20
RD/WT
(EATX) (EATX)
B12 B13
PAIR
TWISTED
TWISTED
PAIR
D1
D1
20
VT/BR
D2
20
WT/BK
(8W-31-4)
(8W-30-11)
(8W-30-17)
(8W-30-4) (8W-30-4)
(8W-30-4) (8W-30-4)
(8W-30-4) (8W-45-3)
(8W-30-4)
(8W-30-4)
(8W-12-2)
(8W-10-16)
(8W-12-9)
8W - 40 - 6 8W-40 INSTRUMENT CLUSTER
GAS
NS/GS
J988W-3 GS004006
43
VEHICLE
SPEED
POWERTRAIN
CONTROL
MODULE
WT/BK
20
D2
VT/BR
20
D1
BODY
CONTROL
MODULE
9 10
WT/BK
20
D2 D1
20
VT/BR
(+)
C2 3
CCD
BUS
(-)
C2 34
CCD
BUS
PS01 PS02
CCD
BUS
(+) (-)
BUS
CCD
TACHOMETER
CONTROL
TACHOMETER
CONTROL
SPEEDOMETER
SPEEDOMETER
BATT M1
CLUSTER
INSTRUMENT
B(+)
FUSED
ST-RUN-OFF F11
FUSED
IGN.
(ST-RUN-OFF)
PAIR
TWISTED
42 C1
SPEED
VEHICLE
SENSOR
SIGNAL
3
VEHICLE
SPEED
SENSOR
WT/OR
18
G7
VEHICLE
SPEED
SENSOR
SIGNAL
BS30
B108
E96
4
G7
18
WT/OR
G7
18
WT/OR
G7
18
WT/OR
SENSOR
SPEED
ENGINE
3
GY/BK
18
K24
5 E97
B106
K24
20
GY/BK
SPEED
ENGINE
8
SENSOR
2
SIGNAL
ENGINE
SPEED
SENSOR
SIGNAL
SIGNAL
SENSOR
ENGINE
SPEED
C1 75
VT/RD
20
K159
Z122
18
BK
ES30
7
G301
6
Z12
18
BK
Z1
18
BK
BS40
FROM
TWISTED
PAIR
SHIELD
Z122
18
BK
SIGNAL
SENSOR
SPEED
ENGINE
SENSOR
SIGNAL
(8W-30-35)
(8W-30-36)
(8W-45-3)
(8W-45-9)
(8W-30-31) (8W-30-31)
(8W-10-11) (8W-12-9)
(8W-30-36) (8W-30-35)
(8W-15-3)
(8W-15-12)
(8W-15-3)
NS/GS 8W-40 INSTRUMENT CLUSTER
DIESEL
8W - 40 - 7
GS004007 J988W-3
LAMP
INDICATOR
VOLTS
CHARGING
SYSTEM
CONTROL
INDICATOR
SIGNAL
SENSOR
COOLANT
ENGINE
26 C1
TEMPERATURE
TN/BK
18
K2
E78
F02
11
E69
F09
12
TN/BK
18
K2
2.4L 3.3L/3.8L
OTHERS 2.0L
ENGINE
COOLANT
TEMPERATURE
SENSOR
2
GAUGE
TEMPERATURE
COOLANT
ENGINE
ENGINE
COOLANT
TEMPERATURE
CONTROL
GAUGE
MODULE
CONTROL
POWERTRAIN
PS02
PS01
WT/BK
18
D2
VT/BR
18
D1
(+)
C2 59
CCD
BUS
(-)
C2 60
CCD
BUS
12 13 P18
B23
BS05 BS06
B33 2
7
E36
ES13 ES14
D2
18
WT/BK
D1
18
VT/BR
CCD
BUS
(-) (+)
BUS
CCD
BUS
CCD
34 C2
(-)
BUS
CCD
3 C2
(+)
VT/BR
20
D1 D2
20
WT/BK
10 9
MODULE
CONTROL
BODY
D1
20
VT/BR
D2
20
WT/BK
RD/WT
20
F11
FUSED
IGNITON
(ST-RUN-OFF)
11
C4
10
INSTRUMENT
CLUSTER
2
FUSE
10A
ST-RUN-OFF A81
BLOCK
JUNCTION
B12 B13
(EATX) (EATX)
PAIR
TWISTED
TWISTED
PAIR
D2
20
WT/BK
D1
20
VT/BR
D1
(8W-30-10)
(8W-30-16)
(8W-30-24)
(8W-30-4)
(8W-30-4)
(8W-30-4)
(8W-30-4) (8W-30-4)
(8W-30-4) (8W-30-4)
(8W-45-3)
(8W-12-9)
(8W-10-16)
(8W-12-2)
GAS
NS/GS
J988W-3 GS004008
LAMP
INDICATOR
VOLTS
CHARGING
SYSTEM
CONTROL
INDICATOR
SIGNAL
SENSOR
COOLANT
ENGINE
60 C1
TEMPERATURE
B33
E120
3
ENGINE
COOLANT
TEMPERATURE
SENSOR
GAUGE
TEMPERATURE
COOLANT
ENGINE
ENGINE
COOLANT
TEMPERATURE
CONTROL
GAUGE
PS02
PS01
CCD
BUS
(-) (+)
BUS
CCD
BUS
CCD
34 C2
(-)
BUS
CCD
3 C2
(+)
VT/BR
20
D1 D2
20
WT/BK
10 9
MODULE
CONTROL
BODY
D1
20
VT/BR
D2
20
WT/BK
FUSED
IGNITION
(ST-RUN-OFF)
INSTRUMENT
CLUSTER
ST-RUN-OFF F11
3
G58
20
BK/YL
BATT M1
B(+)
FUSED
PAIR
TWISTED
BK/YL
20
G58
PK
20
D21
61
POWERTRAIN
CONTROL
MODULE
SCI
TRANSMIT
7
3 11
D1
20
VT/BR
D2
20
WT/BK
17
B23
P18
B17
D21
20
PK
TWISTED
PAIR
TWISTED
PAIR
DATA
LINK
CONNECTOR
TEMPERATURE
ENGINE
COOLANT
SENSOR
SIGNAL
(8W-30-36)
(8W-30-31)
(8W-30-31)
(8W-45-3)
(8W-45-9)
(8W-12-9) (8W-10-11)
(8W-30-30)
(8W-30-30)
(8W-30-31)
DIESEL
8W - 40 - 9
GS004009 J988W-3
SENSE
WASHER
58 C1
SWITCH
G29
20
BK/TN
WT
20
V37
WT
20
V37
B
SWITCH
FLUID
WASHER
LOW
8
B70
E43
21 P34
B23
RD/LG
20
V37
RIGHT
SPEED
CONTROL
SWITCH SWITCH
CONTROL
SPEED
LEFT
CLOCKSPRING
4
LAMP
INDICATOR
LEVEL
WASHER
LOW
JUNCTION
BLOCK
ST-RUN-OFF A81
10A
FUSE
2
CLUSTER
INSTRUMENT
10
C4
11
(ST-RUN-OFF)
IGNITION
FUSED
F11
20
RD/WT
WT/BK
20
D2
VT/BR
20
D1
BODY
CONTROL
MODULE
9 10
WT/BK
20
D2 D1
20
VT/BR
(+)
C2 3
CCD
BUS
(-)
C2 34
CCD
BUS
CCD
BUS
(+) (-)
BUS
CCD
VT/BR
18
D1
WT/BK
18
D2
E36
7
2 B33
BS06 BS05
B23
P18 13 12
BUS
CCD
60 C2
(-)
BUS
CCD
59 C2
(+)
D1
18
VT/BR
D2
18
WT/BK
PS01
PS02
POWERTRAIN
CONTROL
MODULE
V37
18
RD/LG
SWITCH
C2 41
SPEED
CONTROL
SIGNAL
LAMP
INDICATOR
CRUISE
CRUISE
INDICATOR
CONTROL
LAMP INDICATOR
CONTROL
LEVEL
FLUID
LOW
WASHER
FLUID
(EATX)
ES14 ES13
(EATX)
B12 B13
A21
PAIR
TWISTED
PAIR
TWISTED
C2
V37
20
RD/LG
D1
20
VT/BR
D2
20
WT/BK
D1
FLUID
WASHER
FLUID
SWITCH
SENSE
(8W-53-3)
(8W-33-2) (8W-33-2)
(8W-12-2)
(8W-10-16)
(8W-12-9)
(8W-45-3)
(8W-30-4) (8W-30-4)
(8W-30-4)
(8W-30-4)
(8W-30-4)
(8W-30-5)
(8W-30-4) (8W-30-4)
GAS
NS/GS
J988W-3 GS004010
SWITCH
WASHER
SENSE
58 C1
FLUID
G29
20
BK/TN
WT
20
V37
B
SWITCH
FLUID
WASHER
LOW
21 P34
B23
RD/LG
20
V37
RIGHT
SPEED
CONTROL
SWITCH SWITCH
CONTROL
SPEED
LEFT
CLOCKSPRING
4
LAMP
INDICATOR
LEVEL
WASHER
LOW
BATT M1
CLUSTER
INSTRUMENT
B(+)
FUSED
WT/BK
20
D2
VT/BR
20
D1
BODY
CONTROL
MODULE
9 10
WT/BK
20
D2 D1
20
VT/BR
(+)
C2 3
CCD
BUS
(-)
C2 34
CCD
BUS
CCD
BUS
(+) (-)
BUS
CCD
POWERTRAIN
CONTROL
MODULE
SWITCH
36
SPEED
CONTROL
SIGNAL
LAMP
INDICATOR
CRUISE
CRUISE
INDICATOR
CONTROL
LAMP INDICATOR
CONTROL
LEVEL
FLUID
LOW
WASHER
FLUID
A21
V37
20
RD/LG
ST-RUN-OFF F11
FUSED
IGNITION
(ST-RUN-OFF)
PS02 PS01
PAIR
TWISTED
V37
22
WT
DRIVER
CONTROL
SPEED
LAMP
LB/RD
20
V38
LAMP
C1 56
SPEED
CONTROL
DRIVER
LB/RD
20
V38
27
TWISTED
PAIR
C2
WASHER
FLUID
SWITCH
SENSE
(8W-53-3)
(8W-33-4) (8W-33-4)
(8W-10-11)
(8W-45-3)
(8W-45-9)
(8W-30-39)
(8W-12-9)
(8W-30-31) (8W-30-31)
DIESEL
8W - 40 - 11
GS004011 J988W-3
8W-41 HORN/CIGAR LIGHTER/POWER OUTLET
Component Page
BS19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-41-2
Ci gar/Accessory Rel ay . . . . . . . . . . . . . . . . . .8W-41-3
Cl ockspri ng . . . . . . . . . . . . . . . . . . . . . . . . . .8W-41-2
Front Ci gar Li ghter/Power Outl et . . . . . . . . .8W-41-3
Fuse 8 (PDC). . . . . . . . . . . . . . . . . . . . . . . . .8W-41-3
Fuse 9 (PDC). . . . . . . . . . . . . . . . . . . . . . . . .8W-41-2
G200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-41-3
G300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-41-3
G301 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-41-2
Component Page
G302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-41-3
Hi gh Note Horn. . . . . . . . . . . . . . . . . . . . . . .8W-41-2
Horn Rel ay . . . . . . . . . . . . . . . . . . . . . . . . . .8W-41-2
Horn Swi tch . . . . . . . . . . . . . . . . . . . . . . . . .8W-41-2
Juncti on Bl ock . . . . . . . . . . . . . . . . . . . . . .8W-41-2, 3
Low Note Horn . . . . . . . . . . . . . . . . . . . . . . .8W-41-2
PTC 7 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . .8W-41-3
Rear Ci gar Li ghter/Power Outl et . . . . . . . . .8W-41-3
NS/GS 8W - 41 HORN/CIGAR LIGHTER/POWER OUTLET 8W - 41 - 1
85 87
30 86
RELAY
HORN
C2
4 8
C2
20A
FUSE
9
BATT A0
POWER
DISTRIBUTION
CENTER
JUNCTION
BLOCK
BODY
CONTROL
MODULE
RELAY
HORN
18
CONTROL
C2 4
GY/OR
20
X4
HORN
NOTE
LOW HIGH
NOTE
HORN
X2
18
DG/RD
X2
18
DG/RD
X2
18
DG/RD
BS19
A A
B B
Z1
18
BK
Z1
18
BK
G301
CLOCKSPRING
HORN
SWITCH
13 1
RELAY
CONTROL
20
C2
1 C2
X3
20
BK/RD
HORN
(8W-10-30)
(8W-10-8)
(8W-10-10)
(8W-12-2)
(8W-45-3)
(8W-15-10)
(8W-15-11)
8W - 41 - 2 8W-41 HORN/CIGAR LIGHTER/POWER OUTLET NS/GS
J988W-3 GS004102
DB
20
F1
C2 9
POWER
DISTRIBUTION
CENTER
BATT A0
8
FUSE
20A
CIGAR/
ACCESSORY
86 30
87 85
RELAY
C2
16
PTC
7
9A
RUN-ACC A31
JUNCTION
BLOCK
BK
18
Z1
2
C4
Z1
16
BK BK
16
Z1
RD
16
F30
RD
16
F30
REAR
CIGAR
LIGHTER/
POWER
OUTLET
1
3
RD
16
F30
C2
10
P34
B23 A22
3
1
G200
10
G302
11 10
G300
FRONT
CIGAR
LIGHTER/
22
*2
C1
11
E2
20
OR
A/C
HEATER
CONTROL
* BUILT-UP-EXPORT
OUTLET
POWER
PANEL
LAMPS
FEED
(8W-10-10)
(8W-10-8)
(8W-10-31)
(8W-12-16)
(8W-10-16)
(8W-12-2)
(8W-15-4) (8W-15-13) (8W-15-7)
(8W-42-3)
NS/GS 8W-41 HORN/CIGAR LIGHTER/POWER OUTLET 8W - 41 - 3
GS004103 J988W-3
8W-42 AIR CONDITIONING-HEATER
Component Page
A/C Compressor Cl utch . . . . . . . . . . . . . . .8W-42-7, 9
A/C Compressor Cl utch Rel ay . . . . . . . . . .8W-42-7, 9
A/C Heater Control . . . . . . . . . . . .8W-42-2, 3, 4, 5, 6
A/C On I ndi cator . . . . . . . . . . . . . . . . . . . . . .8W-42-4
A/C Pressure Transducer . . . . . . . . . . . . . .8W-42-7, 9
A/C Swi tch . . . . . . . . . . . . . . . . . . . . . . . . . .8W-42-4
A/C Zone Door Actuator . . . . . . . . . . . . . . . . .8W-42-5
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-42-9
Bl end Door Actuator . . . . . . . . . . . . . . . . . . .8W-42-5
BS17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-42-6
BS34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-42-9
Di esel Power Rel ay . . . . . . . . . . . . . . . . . . . .8W-42-9
Dri vers Si de Radi ator Fan . . . . . . . . . . . . .8W-42-10
El ectri c Wi per De-I cer . . . . . . . . . . . . . . . . . .8W-42-3
ES01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-42-9
ES02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-42-7, 9
ES03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-42-7
ES06 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-42-9
ES07 . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-42-7, 10
ES09 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-42-10
ES12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-42-10
ES21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-42-7
ES23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-42-7, 8
ES29 . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-42-9, 10
Evaporator Temperature Sensor . . . . . . . . . .8W-42-5
Front Bl ower Motor . . . . . . . . . . . . . . . . . . . .8W-42-2
Front Bl ower Motor Rel ay . . . . . . . . . . . . . . .8W-42-2
Front Bl ower Motor Resi stor Bl ock . . . . . . . .8W-42-2
FS01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-42-7
Fuse 6 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . .8W-42-4
Fuse 11 (JB) . . . . . . . . . . . . . . . . . . . . . . . . .8W-42-6
Fuse 11 (PDC) . . . . . . . . . . . . . . . . . . . . . .8W-42-7, 9
Fuse 12 (JB) . . . . . . . . . . . . . . . . . . . . . . . . .8W-42-2
Fuse 17 (PDC). . . . . . . . . . . . . . . . . . . . . . . .8W-42-9
Fuse 21 (PDC). . . . . . . . . . . . . . . . . . . . . . . .8W-42-2
Fuse 24 (PDC) . . . . . . . . . . . . . . . . . . . . .8W-42-8, 10
G100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-42-9
G102 . . . . . . . . . . . . . . . . . . . . . . . . . .8W-42-7, 8, 10
G103 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-42-9
Component Page
G200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-42-3, 4
G201 . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-42-2, 3, 6
G300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-42-2
G302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-42-6
HVAC Control . . . . . . . . . . . . . . . . . .8W-42-2, 3, 4, 5
I l l umi nati on Lamp . . . . . . . . . . . . . . . . . . . .8W-42-3
I nstrument Cl uster . . . . . . . . . . . . . . . . . . . .8W-42-3
JS01b . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-42-5
JS02b . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-42-5
JS03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-42-5
Juncti on Bl ock . . . . . . . . . . . . . . . .8W-42-2, 3, 4, 6, 7
Message Center . . . . . . . . . . . . . . . . . . . . . . .8W-42-4
Mode Door Actuator . . . . . . . . . . . . . . . . . . .8W-42-5
Passengers Si de Radi ator Fan . . . . . . . . . .8W-42-10
Power Di stri buti on Center . . . . . .8W-42-2, 7, 8, 9, 10
Powertrai n Control Modul e . . . . .8W-42-3, 7, 8, 9, 10
PTC 1 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . .8W-42-7
Radi ator Fan Di sconnect . . . . . . . . . . . . . . .8W-42-10
Radi ator Fan No. 1 . . . . . . . . . . . . . . . . . . . .8W-42-8
Radi ator Fan No. 2 . . . . . . . . . . . . . . . . . . . .8W-42-8
Radi ator Fan Rel ay . . . . . . . . . . . . . . . . . . . .8W-42-8
Radi ator Fan Rel ay No. 1 . . . . . . . . . . . . . .8W-42-10
Rear A/C Heater Uni t . . . . . . . . . . . . . . . . . .8W-42-6
Rear Bl ower Front Control Swi tch . . . .8W-42-2, 3, 6
Rear Bl ower Rear Control Swi tch . . . . . . . . .8W-42-6
Rear Defogger On I ndi cator . . . . . . . . . . . . . .8W-42-4
Rear Washer Swi tch . . . . . . . . . . . . . . . . . . .8W-42-3
Rear Wi ndow Defogger Rel ay . . . . . . . . . . . .8W-42-4
Rear Wi ndow Defogger Swi tch . . . . . . . . . . .8W-42-4
Rear Wi per Del ay On I ndi cator . . . . . . . . . . .8W-42-3
Rear Wi per Del ay Swi tch . . . . . . . . . . . . . . .8W-42-3
Rear Wi per On I ndi cator . . . . . . . . . . . . . . . .8W-42-3
Rear Wi per On Swi tch. . . . . . . . . . . . . . . . . .8W-42-3
Reci rcul ate Mode I ndi cator . . . . . . . . . . . . . .8W-42-4
Reci rcul ate Mode Swi tch . . . . . . . . . . . . . . . .8W-42-4
Reci rcul ati on Door Actuator . . . . . . . . . . . . .8W-42-5
RF3 E40 . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-42-8
RFS1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-42-8
RFS2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-42-8
NS/GS 8W - 42 AIR CONDITIONING-HEATER 8W - 42 - 1
7
C2
POWER
DISTRIBUTION
CENTER
40A
FUSE
21
85 87
30 86
FRONT
BLOWER
MOTOR
RELAY
5 C2
3
C1 C4
2
BLOCK
JUNCTION
12
FUSE
10A
BATT A0
RUN A22
F20
20
WT
1
2
MOTOR
BLOWER
FRONT
B23
P18
C71
12
DB
Z1
18
BK
C2 8
5 0
1
2 3
4
A/C
HEATER
CONTROL
3 C2 7 C2 C2 4 C2 2 10 C2
C7
12
BK/TN
B35
10 1 3 5 6
FRONT
BLOWER
MOTOR
RESISTOR
BLOCK
B31
B23
P18
B30 B33 B34 B32
C4
16
TN
C5
16
LG
C6
14
LB
C104
12
RD/WT
C107
12
TN/BK
TN/BK
12
C107
RD/WT
12
C104
LB
14
C6
LG
16
C5
TN
16
C4
HVAC
CONTROL
FRONT
BLOWER
OFF
GROUND
G300
BK
12
Z1
C2
6
G201
7
10
SWITCH
CONTROL
FRONT
BLOWER
REAR
Z1
12
BK
4 M3
2 M1
3 M2
1 LOW
0 OFF
5 HIGH
35
32 34 33 30 31
GROUND
M
(8W-10-8)
(8W-10-18)
(8W-12-2)
(8W-12-12)
(8W-10-8)
(8W-10-14)
(8W-15-7)
(8W-15-4)
(8W-42-6)
8W - 42 - 2 8W-42 AIR CONDITIONING-HEATER NS/GS
J988W-3 GS004202
A/C
HEATER
CONTROL
HVAC
CONTROL
MODE
SELECT
GROUND
4
3
2
1 5
SENSE
CONTROL
LEFT TEMP.
REAR
WASHER
SWITCH
SENSE
11 C1
6
C2
21
C1
G201
7
SWITCH
CONTROL
FRONT
BLOWER
REAR
Z1
12
BK
Z1
12
BK
SENSE
SWITCH
DELAY
LAMP
ILLUMINATION
REAR
WIPER
DELAY
SWITCH
DELAY ON
INDICATOR
DRIVER
ON
DELAY
WIPER
REAR
SWITCH
ON
WIPER
REAR
SWITCH
WIPER ON
INDICATOR
REAR
WIPER
ON
INDICATOR
DRIVER
INDICATOR
WIPER ON
REAR
WASHER
SWITCH
RIGHT
TEMP.
CONTROL
GROUND
BK/LG
18
Z2
G200
5
2
PANEL
LAMPS
DRIVER
BODY
CONTROL
MODULE
C4
8
BLOCK
JUNCTION
6
CLUSTER
INSTRUMENT
E2
20
OR
E2
20
OR
WASH
WIPE/
REAR
C1 2
38
C2
SWITCH
WIPEER
REAR
V26
22
YL/WT
37
SIGNAL
SWITCH
A/C
POWERTRAIN
CONTROL
MODULE
SIGNAL
SWITCH
A/C ON-OFF
C1 3
C103
20
DG/LB
P18
B23 B36
SENSE
DRIVER
WIPER DE-ICE
ELECTRIC
ELECTRIC
WIPER
DE-ICER
C1 7
C66
18
BK/WT
MODULE
CONTROL
POWERTRAIN
A/C
SWITCH
SIGNAL
38
C1
1
DG/LB
18
C103
E43
B70
GAS DIESEL
C103
20
DG/LB
36
1 PANEL
2 BI-LEVEL
4 MIX
3 FLOOR
5 DEFROST
E2
20
OR
FRONT
CIGAR
LIGHTER/
POWER
OUTLET
TO
1
C2
MUX
FEED
LAMPS
PANEL
WIPER
DE-ICER
SWITCHED
GROUND
GROUND
(8W-15-4)
(8W-42-6)
(8W-15-4)
(8W-45-5)
(8W-45-6)
(8W-12-2)
(8W-40-4)
(8W-30-37) (8W-30-5)
(8W-41-3)
(8W-12-23)
NS/GS 8W-42 AIR CONDITIONING-HEATER 8W - 42 - 3
GS004203 J988W-3
A/C
HEATER
CONTROL
HVAC
CONTROL
A/C
ON/OFF
SWITCH
SENSE
21
C1
REAR
WINDOW
DEFOGGER
SWITCH
ON
DEFOGGER
REAR
SWITCH
MODE
RECIRCULATE
SWITCH SENSE
MODE
INDICATOR
A/C
ON
INDICATOR
DRIVER
INDICATOR
A/C ON
A/C
SWITCH
BK/LG
18
Z2
G200
5
BLOCK
JUNCTION
INDICATOR
MODE
RECIRCULATE
REAR WINDOW
DEFOGGER
RELAY CONTROL
10 C1 C1 1
(RUN)
IGNITION
FUSED
14
C4
BR/PK
18
V23
20A
FUSE
6
ST-RUN A21
C14
22
WT/RD
C4
32
DRIVER
INDICATOR
MODE
RECIRCULATE
SWITCH SENSE
DEFOGGER
WINDOW
REAR
10
CENTER
MESSAGE
V23
18
BR/PK
REAR
WINDOW
DEFOGGER
RELAY
85
86
RECIRCULATE
(8W-15-4)
(8W-12-2)
(8W-12-9)
(8W-10-16)
(8W-46-2)
(8W-48-2)
J988W-3 GS004204
A/C
HEATER
CONTROL
HVAC
CONTROL
19
C1
13 C1
COMMON
DOOR
ZONE
1 5
ZONE
DOOR
DRIVER
C1 15
9 10
ACTUATOR
DOOR
ZONE
2 3 4
C61
20
DB
C61
22
DB
P30
J01D
C62
20
DB/PK
C62
22
DB/PK
4 3 2
BLEND
DOOR
ACTUATOR
5 1
LG
22
C102
11
4 C1
FEEDBACK
DOOR
ZONE
LG
20
C102
JS01B
JS02B
4
C33
20
DB/RD
C1 17
C33
22
DB/RD
BLEND
DOOR
DRIVER
SIGNAL
COMMON
DOOR
12 C1
DB/WT
22
C34
5
DB/WT
20
C34
1 5 1 5
ACTUATOR
DOOR
RECIRCULATION
2 4 3 1 2
ACTUATOR
DOOR
MODE
SENSOR
TEMPERATURE
EVAPORATOR
RECIRC.
DOOR
DRIVER COMMON
DOOR
C1
12
DRIVER
DOOR
MODE
C1
18
JS03
8
C1
TEMP.
SENSOR
SIGNAL
EVAP.
C1
20
SENSOR
GROUND
JS01B
6
C1
SIGNAL
FEEDBACK
MODE DOOR
9
C1
SUPPLY
5V
JS02B
C1 5
BLEND DOOR
FEEDBACK
SIGNAL
C1 20
SENSOR
GROUND SUPPLY
5V
C1 9
C57
20
DB/GY
C57
20
DB/GY
C57
20
DB/GY
C57
22
DB/GY
2 1
C26
22
PK/DB
C26
20
PK/DB
C26
20
PK/DB
C26
20
PK/DB
7
C36
22
RD/WT
C36
20
RD/WT
12 P30
J01D
2 8 1 6 5 3
C32
22
GY/DB
C32
20
GY/DB
C34
20
DB/WT
C34
20
DB/WT
C34
20
DB/WT
C34
22
DB/WT
C26
22
PK/DB
C57
22
DB/GY
C57
20
DB/GY
C57
20
DB/GY
C35
22
DG/YL
C35
20
DG/YL
C21
22
DB/OR
C21
20
DB/OR
C37
22
YL
C37
20
YL
JS03
C34
20
DB/WT
(DUAL
ZONE A/C)
(A/C) (A/C)
M M
M M
A/C
B
(8W-42-6)
TO
P34 A
(8W-42-6)
TO
P34
C34
20
DB/WT
C61
20
DB
C26
20
PK/DB
C57
20
DB/GY
(8W-70-10)
(8W-70-10)
(8W-70-9) (8W-70-10)
(8W-70-10)
(8W-70-9)
NS/GS 8W-42 AIR CONDITIONING-HEATER 8W - 42 - 5
GS004205 J988W-3
8
1
REAR
BLOWER
REAR
CONTROL
SWITCH SWITCH
CONTROL
FRONT
BLOWER
REAR
8
3
3
2 1
0 0
1 2
3
C1
1
2
BODY
CONTROL
MODULE
PANEL
LAMPS
DRIVER
BLOCK
JUNCTION
30
C4
7 4 1 5 2 3
5 4 6
UNIT
HEATER
A/C
REAR
3
C2
12
20A
FUSE
11
RUN A22
C40
12
BR/WT
BS17
5
1 2
E2
20
OR
E2
20
OR
G201
G302
12
A36
P34
B23 A34
C61
20
DB
C34
20
DB/WT
Z1
18
BK
33
P34
B23
Z1
12
BK
31
C50
12
BK/LG
C50
12
BK/LG
C60
16
BK/LB
C60
16
BK/LB
C60
16
BK/LB
C65
14
BK/OR
C70
12
DG
C70
12
DG
C70
12
DG
A35 B23
P34
34 36
A31 A33
35
M M
0 OFF
1 LOW
2 MEDIUM
3 HIGH 3 HIGH
2 LOW
1 REAR
0 OFF
A
(8W-42-5)
B
(8W-42-5)
A/C HEATER
CONTROL
FROM
CONTROL
A/C HEATER
FROM
C34
20
DB/WT
C61
20
DB
(8W-45-5)
(8W-12-2)
(8W-12-11)
(8W-10-14)
(8W-70-3)
(8W-15-4)
(8W-15-13)
(8W-12-23)
J988W-3 GS004206
C6
2
POWER
DISTRIBUTION
CENTER
85 87
30 86
A/C
COMPRESSOR
CLUTCH
RELAY
15A
FUSE
11
BATT A0
7
C6
1
PTC
9A
C1
30
BLOCK
JUNCTION
ST-RUN A21
6 C2
F87
18
WT/BK
C2 61
POWERTRAIN
CONTROL
MODULE
5V
SUPPLY
1
2
CLUTCH
COMPRESSOR
A/C
G102
ES23
C3
18
DB/BK
Z1
18
BK
Z1
12
BK
64 C2
CONTROL
CLUTCH RELAY
COMPRESSOR
A/C
2 1 3
TRANSDUCER
PRESSURE
A/C
SIGNAL
SWITCH
PRESSURE
A/C
42 C2
SENSOR
GROUND
C2 43
C13
18
DB/OR
ES03
K6
18
VT/WT
K6
18
VT/WT
C18
18
DB
6 C6 1 C6
ES07
F87
18
WT/BK
F87
18
BK/WT
3.3L/3.8L 2.0L
K4
18
BK/LB
ES02
ES21
ES21
FS01
BK/LB
18
K4 K4
18
BK/LB
ES21
ES02
2.4L
5
E69
F09
ES02
(8W-10-10)
(8W-10-29)
(8W-10-8)
(8W-12-13)
(8W-12-2)
(8W-10-16)
(8W-30-5)
(8W-15-2)
(8W-15-2)
(8W-70-7)
(8W-12-13)
(8W-70-4)
(8W-70-4)
(8W-70-5)
(8W-70-5) (8W-70-6)
(8W-70-6)
(8W-70-5)
(8W-12-13)
NS/GS 8W-42 AIR CONDITIONING-HEATER
GAS
8W - 42 - 7
GS004207 J988W-3
POWER
DISTRIBUTION
CENTER
C2 73
POWERTRAIN
CONTROL
MODULE
RADIATOR
FAN
RELAY
CONTROL
1
2
NO. 1
FAN
RADIATOR RADIATOR
FAN
NO. 2
2
1
4
3
RELAY
FAN
RADIATOR
24
FUSE
40A
BATT A0
C7
6
G102
RFS2
FUSED
B (+)
FAN
RELAY
CONTROL
RELAY
2
RFS1
1
E40
RF3
C23
12
DG
C23
12
DG
C23
12
DG
C23
12
DG
1
GROUND
ES23
Z1
14
BK
Z1
12
BK
Z1
12
BK
Z1
12
BK
E40
RF3
2
Z1
12
BK
Z1
12
BK
A16
12
GY
M M
LG/DB
14
K173
RADIATOR
OUTPUT
RADIATOR
FAN
(8W-10-8)
(8W-30-5)
(8W-10-15)
(8W-10-8)
(8W-15-2)
(8W-15-2)
8W - 42 - 8 8W-42 AIR CONDITIONING-HEATER
GAS
NS/GS
J988W-3 GS004208
C6
2
POWER
DISTRIBUTION
CENTER
85 87
30 86
A/C
COMPRESSOR
CLUTCH
RELAY
15A
FUSE
11
BATT A0
7
C6
1 C6
19
POWERTRAIN
CONTROL
MODULE
5V
SUPPLY
CLUTCH
COMPRESSOR
A/C
C3
18
DB/BK
28
CONTROL
CLUTCH RELAY
COMPRESSOR
A/C
2 1 3
TRANSDUCER
PRESSURE
A/C
SIGNAL
SWITCH
PRESSURE
A/C
13
SENSOR
GROUND
33
C13
20
DB/OR
K7
20
OR
C18
20
DB
K4
20
BK/LB
2
Z2
18
BK
Z1
16
BK
Z0
10
BK
ES01
ES02
Z0
6
BK
G100
Z0
2
BK
G103
BATTERY
30
87
DIESEL
POWER
RELAY
20A
FUSE
17
BATT A0
C6 5
ES29
ES06
A142
18
DG/OR
A142
18
DG/OR
A142
18
DG/OR
9
E97
B106
C13
20
DB/OR
BS34
1
(8W-10-9)
(8W-10-29)
(8W-10-8)
(8W-30-38)
(8W-20-3)
(8W-15-3)
(8W-15-3)
(8W-30-28)
(8W-10-25)
(8W-10-8)
(8W-10-25)
(8W-10-25)
(8W-70-11)
NS/GS 8W-42 AIR CONDITIONING-HEATER
DIESEL
8W - 42 - 9
GS004209 J988W-3
POWER
DISTRIBUTION
CENTER
6
POWERTRAIN
CONTROL
MODULE
24
FUSE
40A
BATT A0
C7
6
A16
12
GY
NO. 1
RELAY
FAN
RADIATOR
6
RADIATOR
FAN
RELAY
NO. 2
4 8
2 6 6 2
4
NO. 3
RELAY
FAN
RADIATOR
4
3 1
2
ES07
C25
12
YL
LOW
SPEED
RADIATOR
RELAY NO. 2
CONTROL
C24
20
DB/PK
CONTROL
NO.1 & NO.3
RADIATOR
SPEED
HIGH
48
ES09
1
E95
B107
10
B106
E97
ES29
C24
20
DB/PK
C137
20
YL
C137
20
YL
C137
20
YL
A142
18
DG/OR
A142
18
DG/OR
A142
18
DG/OR
C27
12
DB/PK
C27
12
DB/PK
C27
12
DB/PK
BATT A17
ES12
G102
Z1
12
BK
Z1
12
BK
Z1
12
BK
C116
12
LG/WT
DRIVERS
SIDE
RADIATOR
FAN FAN
RADIATOR
SIDE
PASSENGERS
M M
DISCONNECT
FAN
RADIATOR
4 8
2 5
8
A17
12
RD/BK
(8W-10-8)
(8W-30-37)
(8W-10-15)
(8W-10-8)
(8W-10-25)
(8W-15-3)
(8W-15-3)
(8W-10-19)
8W - 42 - 10 8W-42 AIR CONDITIONING-HEATER
DIESEL
NS/GS
J988W-3 GS004210
8W-43 AIRBAG SYSTEM
Component Page
Ai rbag Control Modul e . . . . . . . . . . . . . . .8W-43-2, 3
Ai rbag I ndi cator Lamp . . . . . . . . . . . . . . . . .8W-43-3
Cl ockspri ng . . . . . . . . . . . . . . . . . . . . . . . . . .8W-43-2
Dri ver Ai rbag Squi b . . . . . . . . . . . . . . . . . . .8W-43-2
Fuse 1 (PDC). . . . . . . . . . . . . . . . . . . . . . . . .8W-43-2
Fuse 2 (PDC). . . . . . . . . . . . . . . . . . . . . . . . .8W-43-2
Fuse 6 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . .8W-43-3
Component Page
G204 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-43-2
Juncti on Bl ock . . . . . . . . . . . . . . . . . . . . . . . .8W-43-3
Message Center . . . . . . . . . . . . . . . . . . . . . . .8W-43-3
Passenger Ai rbag Squi b. . . . . . . . . . . . . . . . .8W-43-3
PS01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-43-3
PS02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-43-3
NS/GS 8W - 43 AIRBAG SYSTEM 8W - 43 - 1
10A
FUSE
1
10
C5
C2 2 1 C2 3 C1
FUSED
IGNITION
(RUN) LINE 1
AIRBAG
DRIVER
F14
18
LG/YL
AIRBAG
CONTROL
MODULE
(ST-RUN)
IGNITION
FUSED DRIVER
AIRBAG
LINE 2
C1 4
R43
18
BK/LB
R45
18
DG/LB
AIRBAG
DRIVER
RUN A22
2
FUSE
10A
C5
2
ST-RUN F87
11
C2
GROUND
Z2
18
BK/LG
1 2
SQUIB
POWER
DISTRIBUTION
CENTER
24
B23
P18
F23
18
DB/YL
23
G204
B23
B24
PAIR
TWISTED
CLOCKSPRING
DG/LB
18
R45
BK/LB
18
R43
LINE 1 LINE 2
-EXPORT
F14
18
LG/YL
BUILT-UP EXCEPT BUILT-
UP-EXPORT
F14
20
LG/YL
DB/YL
20
F23
DB/YL
18
F23
UP-EXPORT
EXCEPT BUILT- BUILT-UP
-EXPORT
1 C1 2 C1
(8W-10-35) (8W-10-35)
(8W-10-14) (8W-10-26)
(8W-10-8)
(8W-15-4)
8W - 43 - 2 8W-43 AIRBAG SYSTEM NS/GS
J988W-3 GS004302
PS01 PS02
WT/BK
20
D2
WT/BK
20
D2
VT/BR
20
D1
VT/BR
20
D1
DATA
LINK
CONNECTOR
11 3
CCD
(-)
BUS
3 C2
(+)
BUS
CCD
C2 4
BK/TN
18
R41
7 C2
DRIVER
LAMP
AIRBAG
MESSAGE
CENTER
LAMP
INDICATOR
AIRBAG
10
11
JUNCTION
BLOCK
6
FUSE
20A
C4
14
ST-RUN A21
V23
18
BR/PK
AIRBAG
CONTROL
MODULE
SQUIB
AIRBAG
PASSENGER
LINE 2
AIRBAG
PASSENGER
2 1
2 C1
PASSENGER
AIRBAG
LINE 1
C1 1
R44
18
DG/YL
R42
18
BK/YL
PAIR
TWISTED
TWISTED
PAIR
NO. 1
*9
* RHD
LINE
AIRBAG
PASSENGER PASSENGER
AIRBAG
LINE
NO. 2
WARNING
(8W-30-4)
(8W-30-31)
(8W-30-4)
(8W-30-31)
(8W-30-4)
(8W-30-31)
(8W-46-2)
(8W-12-2)
(8W-12-9)
(8W-10-16)
NS/GS 8W-43 AIRBAG SYSTEM 8W - 43 - 3
GS004303 J988W-3
8W-44 INTERIOR LIGHTING
Component Page
Ash Recei ver Lamp . . . . . . . . . . . . . . . . . . . .8W-44-7
Automati c Day/Ni ght Mi rror . . . . . . . . . . . . .8W-44-6
Back-Up Swi tch. . . . . . . . . . . . . . . . . . . . . . .8W-44-6
Body Control Modul e . . . . .8W-44-2, 3, 4, 5, 6, 7, 8, 9
BS02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-44-6
Center Dome Lamp . . . . . . . . . . . . . . . . . . . .8W-44-4
Courtesy Lamp Rel ay . . . . . . . . . . . . . .8W-44-2, 3, 4
CS01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-44-4
CS02 . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-44-2, 3, 4
CS03 . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-44-2, 3, 4
CS04 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-44-6
CS06 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-44-8
CS1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-44-4
Dri ver Door Courtesy Lamp . . . . . . . . . . . . .8W-44-3
Dri ver Power Mi rror . . . . . . . . . . . . . . . . . . .8W-44-6
Dri ver Power Wi ndow Swi tch . . . . . . . . . . . .8W-44-9
DS01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-44-3, 9
EC1 C19 . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-44-6
Front Readi ng Lamp Defeat Swi tch . . . . . . .8W-44-2
Front Readi ng Lamps/Swi tch . . . . . . . . . . . .8W-44-2
Fuse 1 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . .8W-44-7
Fuse 3 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . .8W-44-7
Fuse 6 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . .8W-44-6
Fuse 12 (JB) . . . . . . . . . . . . . . . . . . . . . . . . .8W-44-6
Fuse 18 (PDC) . . . . . . . . . . . . . . . . . . . .8W-44-2, 3, 4
Fuse 22 (PDC). . . . . . . . . . . . . . . . . . . . . . . .8W-44-7
G200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-44-8
G201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-44-8
G300 . . . . . . . . . . . . . . . . . . . . . . .8W-44-3, 6, 7, 8, 9
G301 . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-44-5, 8, 9
G302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-44-5, 8
Component Page
G400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-44-4, 5
Gl ove Box Lamp . . . . . . . . . . . . . . . . . .8W-44-2, 3, 4
Headl amp Swi tch . . . . . . . . . . . . . . . . . . .8W-44-2, 7
I gni ti on Swi tch . . . . . . . . . . . . . . . . . . . . . . .8W-44-8
I nteri or Lamps On Swi tch . . . . . . . . . . . . . . .8W-44-2
Juncti on Bl ock . . . . . . . . . . . .8W-44-2, 3, 4, 6, 7, 8, 9
Key-I n Hal o Lamp. . . . . . . . . . . . . . . . . . . . .8W-44-3
Left Li ftgate Fl ood Lamp . . . . . . . . . . . . . . .8W-44-4
Left Mi d Readi ng Lamp . . . . . . . . . . . . . . . .8W-44-4
Left Rear Readi ng Lamp . . . . . . . . . . . . . . . .8W-44-4
Left Vi sor/Vani ty Mi rror Lamps . . . . . . . . . .8W-44-3
Message Center . . . . . . . . . . . . . . . . . . . . . . .8W-44-7
Park Lamp Rel ay . . . . . . . . . . . . . . . . . . . . .8W-44-7
Passenger Door Courtesy Lamp. . . . . . . . .8W-44-3, 9
Passenger Power Wi ndow Swi tch . . . . . . .8W-44-3, 9
Radi o. . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-44-7, 8
Rear Bl ower Front Control Swi tch . . . . . . . .8W-44-8
Rear Dome Lamp . . . . . . . . . . . . . . . . . . . . .8W-44-4
Ri ght Li ftgate Fl ood Lamp . . . . . . . . . . . . . .8W-44-4
Ri ght Mi d Readi ng Lamp . . . . . . . . . . . . . . .8W-44-4
Ri ght Rear Readi ng Lamp. . . . . . . . . . . . . . .8W-44-4
Ri ght Vi sor/Vani ty Mi rror Lamps . . . . . . . . .8W-44-3
Transmi ssi on Range Sensor . . . . . . . . . . . . . .8W-44-6
Uni versal Garage Door Opener . . . . . . . . . . .8W-44-8
NS/GS 8W - 44 INTERIOR LIGHTING 8W - 44 - 1
C20
B75
1
5 P18
B23
BR
20
M20
GLOVE
BOX
LAMP
PK/VT
20
F41
C3
20
2
1
CS03
GROUND
LAMP
READING
C1
80
3
B75
C20
22 P18
B23
BK/YL
20
M13
DRIVER
RELAY
LAMP
COURTESY
10
BR/LG
22
M112
17
M113
20
LB/PK BR/WT
22
M111
HEADLAMP
SWITCH
C1
10
C1 11
LAMP
DEFEAT
SWITCH
SWITCH
ON
LAMPS
INTERIOR
9 C1
3
C1
CS02
OTHERS CONSOLE
OVERHEAD
FRONT
READING
LAMPS/
SWITCH
1
4
2
B75
C20
PK/VT
20
F41
28
C3
34
C3
RELAY
LAMP
COURTESY
86 30
87 85
C2
19
PK/VT
20
F41
C2 15
JUNCTION
BLOCK
CENTER
DISTRIBUTION
POWER
18
FUSE
15A
2
C2
BATT A0
READING
FRONT
B22
3
6 2
OVERHEAD
CONSOLE
OTHERS
B5
BODY
CONTROL
MODULE
C3
BLOCK
JUNCTION
PK/VT
F41
20
M20
20
BR
M20
20
BR
M20 20BR
D4
(8W-70-3)
(8W-50-9)
(8W-50-10)
(8W-10-20)
(8W-12-2)
(8W-10-9)
(8W-10-20)
(8W-10-8)
(8W-45-4)
(8W-45-8)
(8W-12-2)
8W - 44 - 2 8W-44 INTERIOR LIGHTING NS/GS
J988W-3 GS004402
C2
29
C3
29
2
1
LAMP
HALO
KEY-IN
M11
20
PK/LB
PK/VT
20
F41
86 30
87 85
C2
19
PK/VT
20
F41
C2 15
JUNCTION
BLOCK
CENTER
DISTRIBUTION
POWER
18
FUSE
15A
2
C2
BATT A0
2
B75
C20
CS02
A
B
LEFT
VISOR/
VANITY
MIRROR
LAMPS LAMPS
MIRROR
VANITY
VISOR/
RIGHT
B
A
BODY
CONTROL
MODULE
GROUND
LAMP
COURTESY
C1 80
M20
20
BR
CS03
C20
1
BR
20
M20
8
G300
36 C4
2
C2
Z1
14
BK
Z1
20
BK
BLOCK
JUNCTION
DRIVER
DOOR
COURTESY
2
1
LAMP
LAMP
1
2
COURTESY
DOOR
PASSENGER
M11
20
PK/LB
3
B01
D02
M11
20
PK/LB
D01P
B03
6
M11
20
PK/LB
5 11
Z1
20
BK
DS01
Z1
12
BK
B02
D01D
10
Z1
20
BK
Z1
18
BK
5
D01P
B03
PASSENGER
POWER
WINDOW
SWITCH
TO
BK
12
Z1
(OVERHEAD
CONSOLE)
M1
20
PK/LB
B75
5
B23
P18
GLOVE
BOX
LAMP
2
M20 20BR
COURTESY
LAMP
RELAY
LAMP
COURTESY
GROUND
(8W-12-2)
(8W-10-9)
(8W-10-20)
(8W-10-8)
(8W-10-20)
(8W-45-8)
(8W-70-3)
(8W-15-6)
(8W-15-7)
(8W-12-2)
(8W-15-7)
(8W-60-3)
(8W-44-2)
(8W-44-2)
(8W-12-19)
NS/GS 8W-44 INTERIOR LIGHTING 8W - 44 - 3
GS004403 J988W-3
PK/LB
20
M11
6
C2
CS01
CS02
P18
B23
5
C1 2
GROUND
LAMP
COURTESY
4
B75
C20
LB/PK
20
M113
2
1 3
2
3 1
LAMP
READING
REAR
LEFT
RIGHT
REAR
READING
LAMP
1 3
2
LAMP
READING
MID
RIGHT
LEFT
MID
READING
LAMP
3 1
2
3
J02A
L15
3
B17
LJ01
PK/LB
20
M11
BK
20
Z1
BK
20
Z1
8
G400
3
LEFT
LIFTGATE
FLOOD
2
1
LAMP
LAMP
1
2
FLOOD
LIFTGATE
RIGHT
C20
B75
2
F41
20
PK/VT
C2
19
RELAY
LAMP
COURTESY
86 30
87 85
PK/VT
20
F41
C2 15
JUNCTION
BLOCK
CENTER
DISTRIBUTION
POWER
18
FUSE
15A
2
C2
BATT A0
C2
22
(OVERHEAD
CONSOLE)
M11
20
PK/LB
3
2
LAMP
DOME
CENTER
REAR
DOME
LAMP
2
3
1
C20
B75
M20
20
BR
M20
20
BR
M2 20BR
80
CS1
CS03
M2
20
BR
M2
20
BR
MODULE
CONTROL
BODY GLOVE
BOX
LAMP
F41
20
PK/VT
D4
GROUND
LAMP
COURTESY
(8W-10-20)
(8W-15-14)
(8W-12-2)
(8W-10-9)
(8W-10-20)
(8W-10-8)
(8W-45-8) (8W-44-2)
(8W-44-2)
J988W-3 GS004404
11
14 8
DRIVER
C1
79
DOOR
AJAR
SWITCH
SENSE
G75
18
TN TN/RD
18
G74
SENSE
SWITCH
AJAR
DOOR
48
C1
PASSENGER
PASSENGER
DOOR
AJAR
SWITCH
SWITCH
AJAR
DOOR
DRIVER
SENSE
SWITCH
AJAR
HOOD
43
C1
G70
18
BR/TN
REAR
LEFT
BODY
CONTROL
MODULE
C1
47
DOOR
AJAR
SWITCH
SENSE
2
LEFT
REAR
DOOR
AJAR
SWITCH
1
1
SWITCH
AJAR
DOOR
REAR
RIGHT
2
G77
18
TN/OR TN/YL
18
G76
SENSE
SWITCH
AJAR
DOOR
77
C1
RIGHT
REAR
Z1
18
BK
Z1
18
BK
G302
G78
18
TN/BK
C1
59
LIFTGATE
AJAR
SWITCH
SENSE
LJ01
B17
4
G78
18
TN/BK
4
J03A
L16
1
3
LIFTGATE
AJAR
SWITCH
G400
Z1
20
BK
G78
18
TN/BK
Z1
18
BK
G301
12
2
1
SWITCH
AJAR
HOOD
(8W-45-7)
(8W-45-8)
(8W-15-13)
(8W-15-14)
(8W-15-10)
GS004405 J988W-3
ST-RUN A21
C1
14
20A
FUSE
6
1
2
MIRROR
DAY/NIGHT
AUTOMATIC
FUSED
IGNITION
(ST-RUN)
GROUND FEED
LAMP
BACK-UP
3
11 B75
C20
V23
18
BR/PK
CS04
V23
18
BR/PK
V23
18
BR/PK
Z1
20
BK
2
Z1
20
BK
12
Z1
20
BK
14
G300
C2
18
6
1
R
TRANSMISSION
RANGE
SENSOR
1
2
L1
18
VT/BK
VT/BK
18
L1
10
E36
B33
EATX MTX
JUNCTION
BLOCK
L1
20
VT/BK
L1
20
VT/BK
C19
EC1
3
L1
20
VT/BK
13
C20
B75
BS02
F20
18
WT
EATX MTX
F20
20
WT
C1 6
DRIVER
POWER
MIRROR
4 C2
5 4
POWER
MIRROR
B(-) B(-)
MIRROR
POWER
5
4
20
C20
B75 19
20 P34
B23
18
A18 A20
P112
20
YL/WT
P112
20
YL/WT
P114
20
YL/BK
P114
20
YL/BK
51
C1
18
7
L24
20
WT/LG
L24
20
WT/LG
L24
20
WT/LG
12
FUSE
10A
RUN A22
BODY
CONTROL
MODULE
AUTOMATIC
HEADLAMP
SIGNAL
6 1 C19
EC1
AUTOMATIC
SIGNAL
HEADLAMP
L1
20
VT/BK
GAS DIESEL
10 10
B33
E120 E36
B33
BACK-UP
SWITCH
5
B33
E36
F20
20
WT
GAS DIESEL
B33
5 5
E120 E36
B33
F20
20
WT
F20
18
WT
F20
20
WT
POWER
MIRROR
B(-)
POWER
MIRROR
B(-)
(8W-10-16)
(8W-12-9)
(8W-12-9)
(8W-15-5)
(8W-31-3)
(8W-12-2)
(8W-70-2)
(8W-62-6)
(8W-12-12)
(8W-10-14)
(8W-45-8)
J988W-3 GS004406
DRIVER
LAMPS
PANEL
23
C4
BLOCK
JUNCTION
G300
8
2
16
BODY
CONTROL
MODULE
PARK
LAMP
RELAY
CONTROL
C1
6
C1 4 5 C1 C1 12
2
C2
1 C2
SWITCH
HEADLAMP
E2
18
OR
2
1
LAMP
RECEIVER
ASH
E2
20
OR
2
C2 C2
11
C2
8
M32
22
BK/LB
E17
20
YL/BK
4
RADIO
E92
22
OR/BK
E17 20 YL/BK
DIMMER
SWITCH
SIGNAL
SWITCH
DIMMER
STEP COURTESY
LAMP
SWITCH
C1
STEP
DIMMER
SWITCH
SIGNAL
SENSE SENSE
21 C4
JUNCTION
BLOCK
BK
14
Z1 BK
18
Z1
C4 22 29 C4
GROUND GROUND
10
C2 C2
14
Z2
20
BK/LG
Z2
20
BK/LG
MESSAGE
CENTER
FROM
C2 2
2 C1
L7
12
BK/YL PK/DB
18
L97
C2 9
C1
4
RELAY
LAMP
PARK
86 30
87 85
CENTER
DISTRIBUTION
POWER
22
FUSE
40A
10
C3
BATT A0
1
10A
FUSE
1 3
FUSE
15A
OUTPUT
RELAY
LAMP
PARK
FUSED
OTHER OVERHEAD
Z1
18
BK
Z1
20
BK
*1
*3
* RHD
(8W-12-2)
(8W-15-6)
(8W-45-4)
(8W-45-5)
(8W-50-9)
(8W-50-10)
(8W-47-2)
(8W-12-2)
(8W-46-4)
(8W-10-8)
(8W-10-17)
(8W-10-8)
(8W-12-8) (8W-12-8)
(8W-12-19)
GS004407 J988W-3
OR
20
E2
5
RADIO
C1
PANEL
LAMPS
BK
20
Z1
OR
20
E2
1
CONTROL
SWITCH
TRACTION
35 C4
BK
20
Z1
OR
20
E2
11
5
POWER
MIRROR
SWITCH
Z1
18
BK
12
G302
G201
Z1
12
BK
BK
12
Z1
SWITCH
IGNITION
2
C2
Z1
20
BK
CLUSTER
INSTRUMENT
13
6
C2
2
JUNCTION
BLOCK
C4 28
G300
8
BK
14
Z1
8
7
SWITCH
CONTROL
FRONT
BLOWER
REAR
E2
20
OR
E2
20
OR
OR
20
E2
REAR
BLOWER
REAR
CONTROL
SWITCH
4
8
HEATER
A/C
11 C1
6
C2
1
C4 C4
8
DRIVER
LAMPS
PANEL
1
C1
2
BODY
CONTROL
MODULE
BLOCK
JUNCTION
3
30
C4
E2
20
OR
GROUND
CONTROL
3
2
BK
16
Z1
G200
10
OUTLET
POWER
LIGHTER/
CIGAR
FRONT
E2
20
OR
5
G301
Z2
18
BK/LG
2
3
LAMPS/
READING
FRONT
(PART OF
OPENER
DOOR
GARAGE
UNIVERSAL
SWITCH)
CS06
9
C20
B75
Z2
18
BK/LG
Z1 20BK
E2 20OR
DRIVER
(8W-47-2)
(8W-35-2)
(8W-62-2)
(8W-62-4)
(8W-15-13)
(8W-10-14)
(8W-40-4)
(8W-12-2)
(8W-15-6)
(8W-42-6)
(8W-42-6)
(8W-42-3)
(8W-45-5)
(8W-12-2)
(8W-15-4)
(8W-41-3)
(8W-15-11)
(8W-49-3)
(8W-49-3)
(8W-12-19)
J988W-3 GS004408
C1
8
2
BODY
CONTROL
MODULE
PANEL
LAMPS
DRIVER
BLOCK
JUNCTION
3
1
3
1
DRIVER
DOOR
LOCK
SWITCH SWITCH
LOCK
DOOR
PASSENGER
3
G301
2
Z2
20
BK/LG
3
3 D01P
B03
BK/LG
20
Z2
Z2
20
BK/LG
Z2
20
BK/LG
D01D
B02
4
11
E2
20
OR
E2
20
OR
SWITCH
WINDOW
POWER
DRIVER
PASSENGER
POWER
WINDOW
SWITCH
E2
20
OR
E2
20
OR
E2
20
OR
E2
20
OR
B03
D01P
14
13
6
7
5
G300
11
Z1
12
BK
DS01
B02
D01D 10
Z1
20
BK
Z1
18
BK
5
2
Z1
20
BK
LAMP
COURTESY
DOOR
PASSENGER
GROUND
(8W-45-5)
(8W-12-2)
(8W-15-10)
(8W-15-11)
(8W-60-2)
(8W-60-3) (8W-61-2)
(8W-61-6)
(8W-61-2)
(8W-61-6)
(8W-15-7)
(8W-15-7)
(8W-44-3)
GS004409 J988W-3
8W-45 BODY CONTROL MODULE
Component Page
A/C Heater Control . . . . . . . . . . . . . . . . . .8W-45-5, 6
Ash Recei ver Lamp . . . . . . . . . . . . . . . . . . . .8W-45-5
Back-Up Swi tch. . . . . . . . . . . . . . . . . . . . . . .8W-45-9
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-45-9
Body Control Modul e . .8W-45-2, 3, 4, 5, 6, 7, 8, 9, 10
BS02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-45-9
BS10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-45-8
BS30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-45-9
Cl ockspri ng . . . . . . . . . . . . . . . . . . . . . . . . . .8W-45-3
Combi nati on Fl asher/DRL Modul e . . . . . . . .8W-45-5
CS03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-45-8
Door Lock Rel ay . . . . . . . . . . . . . . . . . . . . . .8W-45-7
Door Unl ock Rel ay . . . . . . . . . . . . . . . . . . . .8W-45-7
Dri ver Door Lock Swi tch . . . . . . . . . . . . . .8W-45-6, 8
Dri ver Door Unl ock Rel ay . . . . . . . . . . . . . . .8W-45-7
Dri ver Power Mi rror . . . . . . . . . . . . . . . . . .8W-45-10
Dri ver Power Wi ndow Swi tch . . . . . . . . . . . .8W-45-6
Engi ne Cool ant Temperature Sensor . . . . . . .8W-45-9
Engi ne Oi l Pressure Swi tch. . . . . . . . . . . . . .8W-45-7
ES01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-45-9
ES02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-45-9
Front Readi ng Lamps/Swi tch . . . . . . . . . . . .8W-45-8
Front Wi per Swi tch . . . . . . . . . . . . . . . . . . . .8W-45-4
Fuel Tank Modul e . . . . . . . . . . . . . . . . . . .8W-45-7, 9
Fuse 1 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . .8W-45-3
Fuse 2 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . .8W-45-2
Fuse 3 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . .8W-45-3
Fuse 6 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . .8W-45-2
Fuse 19 (PDC). . . . . . . . . . . . . . . . . . . . . . . .8W-45-4
Fuse 22 (PDC). . . . . . . . . . . . . . . . . . . . . . . .8W-45-3
Fuse 28 (PDC). . . . . . . . . . . . . . . . . . . . . . . .8W-45-2
G100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-45-9
G103 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-45-9
G300 . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-45-2, 10
G302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-45-9
Gl ove Box Lamp . . . . . . . . . . . . . . . . . . . . . .8W-45-8
Headl amp Di mmer Swi tch . . . . . . . . . . . . . .8W-45-5
Headl amp Swi tch . . . . . . . . . . . . . . .8W-45-2, 3, 4, 5
Horn Rel ay . . . . . . . . . . . . . . . . . . . . . . . . . .8W-45-3
HVAC Control . . . . . . . . . . . . . . . . . . . . . . . .8W-45-6
I gni ti on Swi tch . . . . . . . . . . . . . . . . . . . . .8W-45-2, 5
Juncti on Bl ock . . . . . . . . . . .8W-45-2, 3, 4, 5, 6, 7, 10
Key-I n Hal o Lamp . . . . . . . . . . . . . . . . . . . .8W-45-10
Component Page
Left Mi d Readi ng Lamp . . . . . . . . . . . . . . . .8W-45-8
Left Rear Readi ng Lamp . . . . . . . . . . . . . . . .8W-45-8
Left Vi sor/Vani ty Mi rror Lamps . . . . . . . . . .8W-45-8
LJ01 B17. . . . . . . . . . . . . . . . . . . . . . . . . .8W-45-4, 6
Low Beam Rel ay . . . . . . . . . . . . . . . . . . . . . .8W-45-5
Low Cool ant Level Swi tch . . . . . . . . . . . . . . .8W-45-9
Low Washer Fl ui d Swi tch . . . . . . . . . . . . . . .8W-45-3
Memory Seat/Mi rror Modul e . . . . . . . . . . .8W-45-2, 6
Message Center . . . . . . . . . . . . . . . . . . . . .8W-45-5, 6
Park Lamp Rel ay . . . . . . . . . . . . . . . . . . . . .8W-45-3
Passenger Door Lock Swi tch . . . . . . . . . . .8W-45-6, 8
Passenger Power Mi rror . . . . . . . . . . . . . . .8W-45-10
Passenger Power Wi ndow Swi tch . . . . . . . . .8W-45-6
Power Di stri buti on Center . . . . . . . . . . .8W-45-2, 3, 4
Power Fol di ng Mi rror Swi tch . . . . . . . . . . .8W-45-10
Power Mi rror Fol d Rel ay . . . . . . . . . . . . . . .8W-45-10
Power Mi rror Unfol d Rel ay . . . . . . . . . . . . .8W-45-10
Powertrai n Control Modul e . . . . . . . . . . . . . .8W-45-9
PS01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-45-3
PS02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-45-3
PTC 3 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . .8W-45-7
Radi o. . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-45-4, 5
Rear Bl ower Front Control Swi tch . . . . . . . .8W-45-5
Rear Washer Motor . . . . . . . . . . . . . . . . . . . .8W-45-4
Rear Wi per Motor . . . . . . . . . . . . . . . . . . . . .8W-45-4
Ri ght Mi d Readi ng Lamp . . . . . . . . . . . . . . .8W-45-8
Ri ght Rear Readi ng Lamp. . . . . . . . . . . . . . .8W-45-8
Ri ght Vi sor/Vani ty Mi rror Lamps . . . . . . . . .8W-45-8
Seat Bel t Swi tch . . . . . . . . . . . . . . . . . . . . . .8W-45-7
Wi per Modul e . . . . . . . . . . . . . . . . . . . . . . . .8W-45-3
Wi per On Rel ay . . . . . . . . . . . . . . . . . . . . . . .8W-45-4
NS/GS 8W - 45 BODY CONTROL MODULE 8W - 45 - 1
BLOCK
JUNCTION
MODULE
CONTROL
BODY
GROUND
C1 13
29
M1
20
PK
FUSED
IGN.
(ST-RUN-OFF)
10A
FUSE
2
B (+)
FUSED
20A
FUSE
6
9 7 12
10
C2
14
GROUND
(ST-RUN)
IGN.
FUSED
BATT A0
28
FUSE
10A
POWER
DISTRIBUTION
CENTER
5
C3
11
BATT M1
IGNITION
SWITCH
2
3
0
2
1 4
A81
20
DG/RD
4 1
2
0
3
9
A21
12
DB
BATT A1
15 C4 31 C4
BK/WT
12
A31
8
3
0
2
1 4
31 C3
14
(RUN-ACC)
IGN.
FUSED
C3 C1 C1
D1
C1
16
MODULE
MIRROR
SEAT/
MEMORY
FUSED
B (+)
PK
20
M1
C2
C4
21
C4
C1 6 C2 2
GROUND
C2
2
Z1
14
BK
G300
8
Z2
20
BK/LG
SWITCH
HEADLAMP
GROUND
4
1 START
2 RUN
3 LOCK
0 OFF
4 ACC
Z2
20
BK/LG
Z1
20
BK
Z1
18
BK
13
GROUND
(8W-12-2)
(8W-12-9)
(8W-12-9)
(8W-10-8)
(8W-10-11)
(8W-10-9)
(8W-10-11)
(8W-10-14)
(8W-10-16)
(8W-62-3)
(8W-63-4)
(8W-15-6)
(8W-50-9)
(8W-50-10)
(8W-12-20) (8W-10-16)
8W - 45 - 2 8W-45 BODY CONTROL MODULE NS/GS
J988W-3 GS004502
DG/WT
20
V7
2
WIPER
MODULE
B
G29
20
BK/TN
SWITCH
FLUID
WASHER
LOW
85
GY/OR
20
X4
18
CONTROL
RELAY
HORN
HORN
RELAY
PARK
LAMP
RELAY
86
POWER
CENTER
DISTRIBUTION
BATT A0
4
C2
JUNCTION
BLOCK
C1
58
BODY
CONTROL
MODULE
22
FUSE
40A
C3
10
L97
18
PK/DB
16
CONTROL
RELAY
LAMP
PARK
85 87
30 86
BK/YL
12
L7
C1
4
15A
FUSE
3
1
OUTPUT
RELAY
LAMP
PARK
FUSED
WASHER
FLUID
SWITCH
SENSE
41
C1
WIPER
PARK
SWITCH
SENSE
C2
8
SWITCH
HEADLAMP
12
E92
22
OR/BK
C1
DIMMER
SWITCH
SIGNAL (+)
BUS
CCD
3
C2
VT/BR
20
D1
PS01
D1
20
VT/BR
PS02
D2
20
WT/BK
C2
34
CCD
BUS
(-)
WT/BK
20
D2
3 11
DATA
LINK
CONNECTOR
4 C2 C2 9
1
FUSE
10A
PAIR
TWISTED
TWISTED
PAIR
2 C1
DIMMER
SWITCH
SIGNAL
WIPER
PARK
SWITCH
SENSE
SENSE
SWITCH
FLUID
WASHER
1 C2
C1
41
CLOCKSPRING
X3
20
BK/RD
RELAY
HORN
CONTROL
CONTROL
HORN
RELAY
(8W-53-3)
(8W-50-11)
(8W-50-12)
(8W-10-9)
(8W-41-2)
(8W-10-8)
(8W-12-2)
(8W-10-17)
(8W-12-8)
(8W-53-2)
(8W-50-9)
(8W-50-10)
(8W-30-4)
(8W-30-31)
(8W-30-4)
(8W-30-31)
(8W-30-4)
(8W-30-31)
(8W-12-8)
(8W-41-2)
NS/GS 8W-45 BODY CONTROL MODULE 8W - 45 - 3
GS004503 J988W-3
7
SIGNAL
MUX
WIPER
3
L307
20
LG/OR
13
C2
6
V52
20
DG/YL
RELAY
ON
WIPER
POWER
DISTRIBUTION
CENTER
CONTROL
WIPER
ON/OFF
RELAY
73
V14
18
RD/VT
BODY
CONTROL
MODULE
JUNCTION
BLOCK
30A
FUSE
19
BATT A0
85
87 86
BR
20
V10
11
20
WIPER
MUX
SIGNAL
FRONT
WASHER
MOTOR
CONTROL
CONTROL
MOTOR
WASHER
FRONT
3
BR/LG
18
V13
49
REAR
WIPER
MOTOR
7
C5
C1 C2 C1
J03A
L16
2
V13
18
BR/LG
LJ01
B17
7
BR/LG
18
V13
REAR
WIPER
MOTOR
CONTROL
MOTOR
WASHER
REAR
V20
20
BK/WT
B
50 C1
CONTROL
MOTOR
WASHER
REAR
C2 C2
C2
40
LG/WT
20
L308
8
SWITCH
HEADLAMP
4
M32
22
BK/LB
2
C2
C1 3
M112
22
BR/LG
17
C1 5
E17
20
YL/BK
11
C2
C1
COURTESY
LAMP SWITCH
SENSE
10
C3
DRIVER
LAMP RELAY
COURTESY
STEP
DIMMER
SWITCH
C1
4
RADIO
YL/BK
20
E17
18 C3
HEADLAMP
SWITCH
SENSE
PARK
LAMP
SWITCH
SENSE SENSE
HEADLAMP
AUTO
C2
C2
12
BK/YL
22
L110
7 C2 2 C1 6
GROUND
C4
21
4
Z1
20
BK
Z1
18
BK
SWITCH)
FUNCTION
MULTI-
(PART OF
SWITCH
WIPER
FRONT
3
GROUND
87A
30
CONTROL
MOTOR
WIPER
REAR
CONTROL
MOTOR
WASHER
REAR
SWITCH
SENSE
STEP
DIMMER
SWITCH
SENSE
(8W-53-2)
(8W-53-3)
(8W-10-8)
(8W-12-2)
(8W-10-19)
(8W-10-8)
(8W-53-4)
(8W-53-4)
(8W-50-9)
(8W-50-10)
(8W-47-2)
(8W-53-2)
(8W-53-3)
(8W-53-5)
J988W-3 GS004504
BODY
CONTROL
MODULE
BLOCK
JUNCTION
15
RELAY
BEAM
LOW
CONTROL
33 C3
L93
22
PK
4
19
SIGNAL
LEFT
REAR
TURN TURN
REAR
RIGHT
SIGNAL
21
5
COMBINATION
FLASHER/
DRL
MODULE
LEFT
REAR
TURN
SIGNAL SIGNAL
TURN
REAR
RIGHT
9
12
CONTROL
RELAY
BEAM
HIGH/LOW
4
C2
C2 1
G26
20
LB
SWITCH
IGNITION
13
BK/OR
22
G69
16 C2
CENTER
MESSAGE
KEY-IN
SWITCH
SENSE FEED
LAMPS
PANEL
2
C4
8 30
INSTRUMENT
CLUSTER
6
11 C1
C4
8
SWITCH
CONTROL
FRONT
BLOWER
REAR
IGNITION
DRIVER
LAMP
INDICATOR
VTSS
OR
20
E2 E2
20
OR
OR
20
E2
23
C4
OR
20
E2
ASH
RECEIVER
LAMP
2
E2
18
OR
C2 1
SWITCH
HEADLAMP
E2
20
OR
C4
1
OR
20
E2
C1 5
RADIO
5
POWER
MIRROR
SWITCH
3
TRACTION
CONTROL
SWITCH
A/C
HEATER
CONTROL
85
(IN PDC)
RELAY
BEAM
LOW
76 C1
L193
20
OR/WT
CONTROL
LOW
BEAM
RELAY
SWITCH)
FUNCTION
MULTI-
(PART OF
SWITCH
DIMMER
HEADLAMP
E2
20
OR
*7
*1
* RHD
86
FRONT
CIGAR
LIGHTER/
POWER
OUTLET
TO
E2
20
OR
FEED
LAMPS
PANEL
FEED
LAMPS
PANEL
FEED
LAMPS
PANEL
FEED
LAMPS
PANEL
FEED
LAMPS
PANEL
FEED
LAMPS
PANEL
FEED
LAMPS
PANEL
PANEL
LAMPS
FEED
KEY-IN
IGNITION
SWITCH
SENSE
VTSS
INDICATOR
LAMP
DRIVER
HIGH/LOW
BEAM
RELAY
CONTROL
(8W-12-2)
(8W-50-2)
(8W-50-12)
(8W-51-3)
(8W-10-14)
(8W-46-2)
(8W-40-4)
(8W-42-6)
(8W-44-7)
(8W-50-9)
(8W-50-10)
(8W-47-2)
(8W-62-2)
(8W-62-4)
(8W-35-2)
(8W-42-3)
(8W-50-2)
(8W-50-2)
(8W-41-3)
GS004505 J988W-3
BODY
CONTROL
MODULE
BLOCK
JUNCTION
38
SWITCH
WIPER
REAR
MUX
V26
22
YL/WT
2
19
LG/RD
20
G96
1 C2
FEED
LAMPS
PANEL
2
1 8
1
E2
20
OR
C1
OR
20
E2
8
D01D
B02
4
OR
20
E2
SWITCH
LOCK
DOOR
DRIVER
E2
20
OR
14
DRIVER
C1
SWITCH
CONTROL
REAR
BLOWER
REAR
PASSENGER
PASSENGER
DOOR
LOCK
SWITCH
E2
20
OR
11
B03
D01P
OR
20
E2
1
WINDOW
SWITCH
POWER
6
OR
20
E2
C2
C1
MODULE
MIRROR
SEAT/
MEMORY
P34
B23
23
G96
20
LG/RD
REAR
WIPE/
WASH
MUX
5
6
RKE MODULE
PROGRAM
GY/BK
22
D9
C2 37
LG/RD
20
G96
MODULE
ENTRY
KEYLESS
REMOTE
RKE
PROGRAM
INTERFACE
RKE
33 C2
G6
22
GY
8
SENSE
SWITCH
PRESSURE
OIL
ENGINE
6
ENGINE
TEMPERATURE
LAMP
DRIVER
VT
22
G2
C2 6
17
C2
16
CONTROLLER
ANTI-LOCK
BRAKE
G19
20
LG/OR
3 P34
B23
A3
LG/OR
18
G19
5
LG/OR
20
G19
CENTER
MESSAGE
ABS
WARNING
LAMP
ABS WARNING
LAMP DRIVER
INTERFACE
RKE
SIGNAL
CENTER
MESSAGE
SIGNAL
A23
C1
44
UNLOCK
LOCK/
LIFTGATE
2
SWITCH
DISARM
ARM/
LIFTGATE
B17
LJ01
6
J03A
L16
6
P98
20
WT/RD
WT/RD
20
P98
WT/RD
20
P98
CONTROL
HVAC
A/C
HEATER
CONTROL
*2
* RHD
*12 *1
C1
POWER
WINDOW
SWITCH
UNIVERSAL
GARAGE
DOOR
OPENER
(PART OF
FRONT READING
LAMPS/SWITCH)
TO
E2
20
OR
WARNING
MUX
LIFTGATE
LOCK/
UNLOCK
MUX
RKE
INTERFACE
WARNING
DRIVER
LAMP
TEMPERATURE
ENGINE ENGINE
OIL
PRESSURE
SWITCH
SENSE
PANEL
LAMPS
FEED
PANEL
LAMPS
FEED
PANEL
LAMPS
FEED
PANEL
LAMPS
FEED
PANEL
LAMPS
FEED
DRIVER
DRIVER
LAMP
WARNING
ABS
(8W-12-2)
(8W-61-2)
(8W-61-6)
(8W-42-6)
(8W-61-2)
(8W-61-6)
(8W-60-3)
(8W-62-3)
(8W-63-4)
(8W-61-5)
(8W-35-3)
(8W-46-2)
(8W-46-2)
(8W-39-3)
(8W-42-3)
(8W-42-3)
(8W-60-2)
(8W-49-3)
J988W-3 GS004506
SIGNAL
SENSOR
LEVEL
FUEL
46
C1
FUEL
TANK
MODULE
DB
18
G4
3
BODY
CONTROL
MODULE
BLOCK
JUNCTION
52
1
8
G6
20
GY
C1 C1
SWITCH
BELT
SEAT
LG/RD
18
G10
1
78
OIL
PRESSURE
SWITCH
SENSE SENSE
SWITCH
BELT
9
B33
E36
GY
16
G6
SWITCH
PRESSURE
OIL
ENGINE
79
G75
18
TN
C1
SWITCH
AJAR
DOOR
DRIVER
DRIVER
DOOR
AJAR
SWITCH
SENSE SENSE
SWITCH
AJAR
DOOR
PASSENGER
C1
TN/RD
18
G74
48
PASSENGER
DOOR
AJAR
SWITCH
LJ01
B17
4
SENSE
SWITCH
AJAR
LIFTGATE
C1
TN/BK
18
G78
3
59
G78
18
TN/BK
4
J03A
L16
TN/BK
18
G78
LIFTGATE
AJAR
SWITCH
1
43
G70
18
BR/TN
C1
HOOD
AJAR
SWITCH
SENSE
HOOD
AJAR
SWITCH
86
85
DOOR
LOCK
RELAY RELAY
UNLOCK
DOOR
85
86
6
85
86
5
RELAY
UNLOCK
DOOR
DRIVER
CONTROL
RELAY
DOOR LOCK DOOR UNLOCK
RELAY
CONTROL
CONTROL
RELAY
UNLOCK
DRIVER
BATT A2
SEAT
3
PTC
9A
(GAS)
ENGINE
ENGINE
OIL
PRESSURE
SWITCH
SENSE
SEAT
BELT
SWITCH
SENSE
FUEL
LEVEL
SENSOR
SIGNAL
LIFTGATE
AJAR
SWITCH
SENSE
HOOD
AJAR
SWITCH
SENSE
3
B13
AW4
(8W-30-6)
(8W-30-20)
(8W-12-2)
(8W-40-4)
(8W-46-2)
(8W-44-5)
(8W-44-5)
(8W-61-3)
(8W-61-4)
(8W-61-7)
(8W-61-8)
(8W-61-3)
(8W-61-4)
(8W-61-7)
(8W-61-8)
(8W-61-7)
(8W-61-8)
(8W-10-13)
(8W-12-14)
(8W-12-15)
GS004507 J988W-3
P97
20
WT/DG
45
11
D01D
B02
2
SWITCH
LOCK
DOOR
DRIVER
DRIVER
DOOR
ARM/
DISARM
SWITCH
2
2
SWITCH
DISARM
ARM/
DOOR
PASSENGER
PASSENGER
DOOR
LOCK
SWITCH
2
B03
D01P
4
WT/LG
20
P96
MUX
SWITCH
DOOR
DRIVER PASSENGER
55 C1
P97
20
WT/DG
WT/LG
20
P96
C1
COURTESY
LAMP
GROUND
80
BR
20
M20
BR
20
M20
LEFT
MID
READING
LAMP
2
2
M20
20
BR
LAMP
READING
REAR
LEFT
6
M20
20
BR
SWITCH
LAMPS/
READING
FRONT
RIGHT
MID
READING
LAMP
BR
20
M20
2
2
M20
20
BR
RIGHT
REAR
READING
LAMP
A
M20
20
BR
LAMPS
MIRROR
VANITY
VISOR/
LEFT
BR
20
M20
RIGHT
VISOR/
VANITY
MIRROR
LAMPS
2
BS10
M20
20
BR
P18
B23
M20
20
BR
GLOVE
BOX
LAMP
CS03
A
2
OTHERS OVERHEAD
CONSOLE
5
B5
B75
C20
1
BR
20
M20
BR
20
M20
2
47
C1
G77
18
TN/OR
SWITCH
AJAR
DOOR
REAR
LEFT RIGHT
REAR
DOOR
AJAR
SWITCH
TN/YL
18
G76
2
C1
77
C1
LEFT
REAR
DOOR AJAR
SWITCH
SENSE SENSE
SWITCH
DOOR AJAR
REAR
RIGHT
7
AUTOMATIC
DAY/NIGHT
MIRROR
AUTOMATIC
HEADLAMP
SIGNAL
51
C1
C20
B75
18
6
C19
EC1
L24
20
WT/LG
MODULE
CONTROL
BODY
OTHER RKE RKE OTHER
P96
20
WT/LG
DOOR
SWITCH
MUX
LEFT
REAR
DOOR AJAR
SWITCH
SENSE
RIGHT
REAR
SWITCH
DOOR AJAR
SENSE
AUTOMATIC
HEADLAMP
SIGNAL
DRIVER
DOOR
SWITCH
MUX
MUX
SWITCH
DOOR
DRIVER
PASSENGER
DOOR
SWITCH
MUX
MUX
SWITCH
DOOR
PASSENGER
GROUND
LAMP
COURTESY
GROUND
LAMP
COURTESY
GROUND
LAMP
COURTESY
GROUND
LAMP
COURTESY
GROUND
LAMP
COURTESY
GROUND
LAMP
COURTESY
GROUND
LAMP
COURTESY
GROUND
LAMP
COURTESY
(8W-61-2)
(8W-61-6)
(8W-39-3)
(8W-39-3)
(8W-61-2)
(8W-61-6)
(8W-44-4)
(8W-44-4)
(8W-44-2)
(8W-44-4)
(8W-44-4)
(8W-44-3)
(8W-44-3)
(8W-44-2)
(8W-70-3)
(8W-44-5) (8W-44-5)
(8W-44-6)
J988W-3 GS004508
3
57
G18
20
PK/BK
C1
MODULE
TANK
FUEL
2
2
BACK-UP
SWITCH
BS02
10
B33
E120
VT/BK
20
L1
SIGNAL
SENSOR
LEVEL
FUEL BACK-UP
LAMP
FEED
G302
5
GROUND
1
Z1
16
BK
L1
20
VT/BK
VT/BK
18
L1
G4
18
DB
C1
46
FUEL
LEVEL
SENSOR
SIGNAL SENSE
SWITCH
LEVEL
COOLANT
1
SWITCH
LEVEL
COOLANT
LOW
2 B33
E120
PK/BK
20
G18
(DIESEL)
2
Z1
20
BK
ES02
ES01
BK
16
Z1
BATTERY
Z0
2
BK
G103 G100
BK
6
Z0
Z1
10
BK
27
SPEED
CONTROL
LAMP
DRIVER
C1
LB/RD
20
V38
56
(DIESEL)
MODULE
CONTROL
POWERTRAIN
3
60
G58
20
BK/YL
C1
SIGNAL
SENSOR
TEMPERATURE
COOLANT
3
COOLANT
TEMPERATURE
SENSOR
(DIESEL)
DRIVER
LAMP
CONTROL
SPEED
75
K159
20
VT/RD
C1
SIGNAL
SENSOR
SPEED
ENGINE
2 59
ENGINE
DISABLE
SIGNAL
C1
OR/BK
20
G55
72
ENGINE
SPEED
SENSOR
SIGNAL
BODY
CONTROL
MODULE
SIGNAL
SENSOR
SPEED
VEHICLE
43
VEHICLE
SPEED
SENSOR
SIGNAL
C1
WT/OR
18
G7
42
G7
18
WT/OR
BS30
G4
18
DB
ENGINE
2
B13
AW4
3
B13
AW4
1
B13
AW4
Z1
14
BK
(DIESEL)
SIGNAL
DISABLE
ENGINE
BACK-UP
LAMP
FEED
ENGINE
COOLANT
TEMPERATURE
SIGNAL
SIGNAL
ENGINE
(8W-51-5)
(8W-70-2)
(8W-15-13)
(8W-15-3)
(8W-15-3)
(8W-20-3)
(8W-30-36)
(8W-30-36)
(8W-30-36)
GS004509 J988W-3
G300
8
Z1
14
BK
JUNCTION
BLOCK
30
C2
85 30
87 86
MIRROR
FOLD
RELAY RELAY
UNFOLD
MIRROR
87A 87 86 87A
30 85
C1
36
C2
2
YL/RD
20
P174
C1 74
MODULE
CONTROL
BODY
P171
20
VT/WT
71 C1
6 C2
5
C2
DRIVER
POWER
MIRROR MIRROR
POWER
PASSENGER
C2
5
C2 6
P159
20
DG
P159
20
DG
P160
20
LB
P160
20
LB
11
C3 C4
11
POWER
FOLDING
MIRROR
SWITCH
2
1
P136
20
YL
SWITCH
MIRROR
FOLDING
39 C2
SIGNAL
36
C4
BK
20
Z1
HALO
KEY-IN
FROM
LAMP
Z1
20
BK
POWER POWER
1 2
M M
1 UNFOLD
2 FOLD
RELAY
FOLD
MIRROR
POWER
RELAY
UNFOLD
MIRROR
POWER POWER
BATT F41
(8W-15-6)
(8W-12-2)
(8W-44-3)
(8W-62-8) (8W-62-8)
(8W-62-8) (8W-62-8)
(8W-62-8)
(8W-10-20)
(8W-12-19)
8W - 45 - 10 8W-45 BODY CONTROL MODULE
BUILT-UP-EXPORT
NS/GS
J988W-3 GS004510
8W-46 MESSAGE CENTER
Component Page
ABS Warni ng Lamp . . . . . . . . . . . . . . . . . . .8W-46-2
Ai rbag Control Modul e . . . . . . . . . . . . . . . . .8W-46-2
Ai rbag Warni ng Lamp . . . . . . . . . . . . . . . . . .8W-46-2
Body Control Modul e . . . . . . . . . . . . . . .8W-46-2, 4, 5
Brake Pressure Swi tch . . . . . . . . . . . . . . . . .8W-46-3
Brake Warni ng Lamp . . . . . . . . . . . . . . . . . .8W-46-3
Combi nati on Fl asher/DRL Modul e. . . . .8W-46-3, 4, 5
Engi ne Cool ant Temperature Lamp. . . . . . . .8W-46-2
Engi ne Oi l Pressure Swi tch. . . . . . . . . . . . . .8W-46-2
Fuse 5 (PDC). . . . . . . . . . . . . . . . . . . . . . . . .8W-46-4
Fuse 6 (JB) . . . . . . . . . . . . . . . . . . . . . . . .8W-46-2, 3
Fuse 28 (PDC). . . . . . . . . . . . . . . . . . . . . . . .8W-46-2
G200 . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-46-3, 4, 5
G300 . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-46-3, 4, 5
Gl ow Pl ug Lamp . . . . . . . . . . . . . . . . . . . . . .8W-46-3
Headl amp Di mmer Swi tch . . . . . . . . . . . . . .8W-46-4
Hi gh Beam I ndi cator . . . . . . . . . . . . . . . . . . .8W-46-4
Component Page
Hi gh Beam Rel ay . . . . . . . . . . . . . . . . . . . . .8W-46-4
I gni ti on Swi tch . . . . . . . . . . . . . . . . . . . . . . .8W-46-3
Juncti on Bl ock . . . . . . . . . . . . . . . . . .8W-46-2, 3, 4, 5
Left Rear Lamp Assembl y . . . . . . . . . . . . . . .8W-46-5
Left Repeater Lamp . . . . . . . . . . . . . . . . . . .8W-46-5
Left Turn I ndi cator . . . . . . . . . . . . . . . . . . . .8W-46-5
Low Beam Rel ay . . . . . . . . . . . . . . . . . . . . . .8W-46-4
Low Oi l Pressure Lamp. . . . . . . . . . . . . . . . .8W-46-2
Message Center . . . . . . . . . . . . . . . . .8W-46-2, 3, 4, 5
Park Brake Swi tch . . . . . . . . . . . . . . . . . . . .8W-46-3
Powertrai n Control Modul e . . . . . . . . . . . . . .8W-46-3
Ri ght Rear Lamp Assembl y . . . . . . . . . . . . . .8W-46-5
Ri ght Repeater Lamp . . . . . . . . . . . . . . . . . .8W-46-5
Ri ght Turn I ndi cator . . . . . . . . . . . . . . . . . . .8W-46-5
Servi ce Engi ne Soon Lamp . . . . . . . . . . . . . .8W-46-3
Turn Si gnal /Hazard Swi tch . . . . . . . . . . . . . .8W-46-5
VTSS Lamp . . . . . . . . . . . . . . . . . . . . . . . . . .8W-46-2
NS/GS 8W - 46 MESSAGE CENTER 8W - 46 - 1
CENTER
MESSAGE
5
LAMP
WARNING
ABS AIRBAG
WARNING
LAMP
11
10
ST-RUN A21
20A
FUSE
6
DRIVER
16
ABS
WARNING
LAMP
BRAKE
ANTI-LOCK
CONTROLLER
R41
18
BK/TN
BLOCK
JUNCTION
C2 7
MODULE
CONTROL
AIRBAG
AIRBAG
WARNING
LAMP
DRIVER
G19
20
LG/OR
A3
P34
G19
18
LG/OR
B23
14
C4
BR/PK
18
V23
C1 10
V23
18
BR/PK
C2
BODY
CONTROL
LAMP
WARNING
ABS
17
DRIVER
MODULE
G19
20
LG/OR
ENGINE
COOLANT
TEMPERATURE
6
LAMP
VT
22
G2
LAMP
6
ENGINE
TEMPERATURE
C2
DRIVER
LAMP
8
PRESSURE
OIL
LOW
SENSE
C2
PRESSURE
OIL
ENGINE
33
SWITCH
G6
22
GY
OIL
PRESSURE
SWITCH
SENSE
52
C1
1
E36
B33
1
G6
16
GY
SWITCH
PRESSURE
OIL
ENGINE
POWER
DISTRIBUTION
CENTER
C3
5
28
FUSE
10A
MEMORY
SEAT/
MODULE
MIRROR
VTSS
LAMP
(ST-RUN)
IGNITION
FUSED
A/C
CONTROL
12
BATT A0
13
16
VTSS
DRIVER
C2
LAMP
BK/OR
22
G69
16 C1
FUSED
B (+)
C4
6
13 C1
M1
20
PK
M1
20
PK
M1
20
PK
3
HEATER
B (+)
FUSED
3
ENTRY
MODULE
KEYLESS
REMOTE
M1 20PK
*8
*7 *9 *12 *1 *2
* RHD
DIESEL GAS
9
B33
E36
G6 20GY
7 P50
NOT
USED
M1
22
PK
WARNING
ENGINE
(8W-12-9)
(8W-10-16)
(8W-35-3)
(8W-12-2)
(8W-43-3)
(8W-45-5)
(8W-45-6)
(8W-10-9)
(8W-10-11)
(8W-62-3)
(8W-63-4)
(8W-42-4)
(8W-10-8)
(8W-61-5)
(8W-12-20)
8W - 46 - 2 8W-46 MESSAGE CENTER NS/GS
J988W-3 GS004602
(ST-RUN)
IGNITION
FUSED
GY/BK
20
G9
Z1
20
BK
14
G200
IGNITION
SWITCH
4 1
2
0
3
2 C1
1
C1
BK
20
Z1
G300
9
SWITCH
PRESSURE
BRAKE
B
1
C2
A
G9
20
GY/BK
GY/BK
20
G9
PARK
BRAKE
SWITCH
C3
9
C3 8
G9
20
GY/BK
JUNCTION
BLOCK
9
BRAKE
WARNING
LAMP
BK/PK
20
G3
BK/PK
20
G3
5
B70
E43
2
DRIVER
LAMP
22
SERVICE
ENGINE
SOON
MODULE
CONTROL
POWERTRAIN
C1
LAMP
SOON
ENGINE
SERVICE
7
CENTER
MESSAGE
10
ST-RUN A21
20A
FUSE
6
BLOCK
JUNCTION
14
C4
BR/PK
18
V23
C1 10
A/C
CONTROL
V23
18
BR/PK
A2
HEATER
GLOW
PLUG
LAMP
7
G85
20
OR/BK
POWERTRAIN
CONTROL
MODULE
26
GLOW
PLUG
LAMP
DRIVER
GAS DIESEL
A17
17
P34
B23
OR/BK
20
G85
10
MODULE
DRL
FLASHER/
COMBINATION
BRAKE
LAMP
SENSE
MTX
1 START
2 RUN
3 LOCK
0 OFF
4 ACC
*13 *11
G3
18
BK/PK
EATX
8
C2
* RHD
INDICATOR
(8W-15-4) (8W-15-8)
(8W-12-2)
(8W-30-13)
(8W-30-19)
(8W-30-27)
(8W-12-9)
(8W-10-16)
(8W-12-2)
(8W-42-4)
(8W-30-32)
(8W-50-13)
(8W-10-14)
NS/GS 8W-46 MESSAGE CENTER 8W - 46 - 3
GS004603 J988W-3
9
HIGH/
LOW
BEAM
RELAY
CONTROL CONTROL
RELAY
BEAM
LOW
HIGH/
C3 33
12 15
RD/OR
20
L34
RD/OR
20
L34
JUNCTION
BLOCK
WT/LG
22
L324
BK
14
Z1
8
G300
C2
2
BK
20
Z1
22 C4
PK
22
L93
MODULE
COMBINATION
FLASHER/
DRL
3
BK
18
Z1
G200
13
21
WT/LG
20
L324
SWITCH
DIMMER
HEADLAMP
12
8
INDICATOR
BEAM
HIGH
P18
B23
18
1
POWER
DISTRIBUTION
CENTER
MESSAGE
CENTER
MODULE
CONTROL
BODY
C3
2
C5
6
5
FUSE
10A
BATT A0
86 30
87 85
B21 B18
10
(PART OF
MULTI-
FUNCTION
SWITCH)
HIGH
BEAM
RELAY
FROM
RELAY
BEAM
LOW
L94
20
OR/WT
*6
*4
* RHD
(8W-12-2)
(8W-15-6)
(8W-50-2)
(8W-15-4)
(8W-10-10)
(8W-45-5)
(8W-10-33)
(8W-10-34)
(8W-10-8)
(8W-50-2)
(8W-50-2)
(8W-12-19)
8W - 46 - 4 8W-46 MESSAGE CENTER NS/GS
J988W-3 GS004604
LEFT
REAR
LAMP
ASSEMBLY
5
DG/RD
18
L63
28
C2
REAR
RIGHT
TURN
SIGNAL
REAR
SIGNAL
TURN
LEFT
BODY
CONTROL
MODULE
BK
18
Z1
COMBO
SWITCHED
GROUND
FLASHER
RIGHT
SIGNAL
SENSE
TURN TURN
SENSE
SIGNAL
LEFT
DB/PK
22
L91 L305
22
LB/WT LB/YL
22
L302
C3
26
C3
4 22
C3
13
G200
TURN
SIGNAL/
HAZARD
SWITCH
3 2
1
1 4 3
8
JUNCTION
BLOCK
3
C4 22
Z1
20
BK
2
C2
G300
8
Z1
14
BK
CENTER
MESSAGE
INDICATOR
TURN
RIGHT LEFT
TURN
INDICATOR
SIGNAL
TURN
RIGHT LEFT
TURN
SIGNAL
DRL
FLASHER/
COMBINATION
MODULE
L63
18
DG/RD
L62
18
BR/RD
REAR REAR
4 2
C3
14 21
C3
BLOCK
JUNCTION
19 21
5 4 8 7 9
MULTI-
FUNCTION
SWITCH)
(PART OF
3 RIGHT
2 LEFT
1 HAZARD
1
1
L62
18
BR/RD
ASSEMBLY
LAMP
REAR
RIGHT
5
36
C2
-EXPORT)
(BUILT-UP
LAMP
REPEATER
RIGHT
L62
18
BR/RD
L63
18
DG/RD
**1
**1
LEFT
REPEATER
LAMP
(BUILT-UP
-EXPORT)
*5 *3
*4
* RHD
** EXCEPT BUILT-UP-EXPORT
5 P50
NOT
USED
L91
20
DB/PK
LEFT
REAR
TURN
SIGNAL
SIGNAL
TURN
REAR
LEFT
RIGHT
REAR
TURN
SIGNAL
RIGHT
REAR
TURN
SIGNAL
(8W-51-4)
(8W-51-5)
(8W-45-5)
(8W-15-4)
(8W-12-2)
(8W-15-6)
(8W-51-3)
(8W-52-2)
(8W-12-2)
(8W-51-4)
(8W-51-5)
(8W-52-3)
(8W-52-2)
(8W-12-19)
NS/GS 8W-46 MESSAGE CENTER 8W - 46 - 5
GS004605 J988W-3
8W-47 AUDIO SYSTEM
Component Page
BS03 . . . . . . . . . . . . . . . . . . . . . . . . .8W-47-4, 5, 6, 7
Bs08 . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-47-5, 6, 7
Fuse 8 (JB) . . . . . . . . . . . . . . . . . . . . . . . .8W-47-2, 4
Fuse 28 (PDC). . . . . . . . . . . . . . . . . . . . . . . .8W-47-2
G202 . . . . . . . . . . . . . . . . . . . . . . . . .8W-47-2, 5, 6, 7
G300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-47-4
Headl amp Swi tch . . . . . . . . . . . . . . . . . . . . .8W-47-2
Juncti on Bl ock . . . . . . . . . . . . . . . . . . . . . .8W-47-2, 4
Left Door Speaker . . . . . . . . . . . . . . . . .8W-47-4, 6, 7
Left Front Panel Speaker . . . . . . . . . . . . .8W-47-6, 7
Left Front Speaker . . . . . . . . . . . . . . . . . . . .8W-47-3
Left Rear Pi l l ar Speaker . . . . . . . . . . . . . . . .8W-47-5
Component Page
Left Rear Speaker . . . . . . . . . . . . . . . . .8W-47-3, 4, 5
Name Brand Speaker Rel ay . . . . . . . . . . . . .8W-47-4
PS01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-47-2
PS02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-47-2
Radi o . . . . . . . . . . . . . . . . . . . . .8W-47-2, 3, 4, 5, 6, 7
Radi o Choke . . . . . . . . . . . . . . . . . . .8W-47-4, 5, 6, 7
Ri ght Door Speaker . . . . . . . . . . . . . . . .8W-47-4, 6, 7
Ri ght Front Panel Speaker . . . . . . . . . . . .8W-47-6, 7
Ri ght Front Speaker . . . . . . . . . . . . . . . . . . .8W-47-3
Ri ght Rear Pi l l ar Speaker . . . . . . . . . . . . . . .8W-47-5
Ri ght Rear Speaker . . . . . . . . . . . . . . . .8W-47-3, 4, 5
NS/GS 8W - 47 AUDIO SYSTEM 8W - 47 - 1
POWER
DISTRIBUTION
CENTER
28
FUSE
10A
BATT A0
C3
5
BLOCK
JUNCTION
C3
24
10A
FUSE
8
C2
11
BODY
CONTROL
MODULE
STEP
DIM
SWITCH
SIGNAL
B (+)
FUSED
9
FEED
LAMPS
PANEL
2
1
C4 C4
17
RUN-ACC A31
13 C1
M1
20
PK
C1
16
FUSED
B (+)
M1
20
PK
C1 6
RADIO
FUSED
IGNITION
(RUN-ACC)
SIGNAL
SWITCH
DIMMER
STEP
4 C1
PANEL
LAMPS
C1 5
FUSED
B (+)
C1 7
C1
5
SENSE
SWITCH
DIMMER
STEP
SWITCH
HEADLAMP
E17
20
YL/BK
E17
20
YL/BK
X12
18
RD/WT
5
POWER
MIRROR
SWITCH
E2
20
OR
E2
20
OR
GROUND
G202
CCD
BUS
(+)
C3 1
(-)
BUS
CCD
2 C3
D1
20
VT/BR
D2
20
WT/BK
M1
20
PK
M1
20
PK
16
DATA
LINK
CONNECTOR
MODULE
MIRROR
SEAT/
MEMORY
TO
PS01 PS02
TO
6 P50
NOT
USED
X12
20
RD/WT
X15 16BK/DG
PANEL
LAMP
FEED
FEED
(8W-10-9)
(8W-10-11)
(8W-10-8)
(8W-12-2)
(8W-12-11)
(8W-45-2)
(8W-45-4)
(8W-45-5)
(8W-10-16)
(8W-50-9)
(8W-50-10)
(8W-62-2)
(8W-62-4)
(8W-15-5)
(8W-30-3)
(8W-30-30)
(8W-62-3)
(8W-30-4) (8W-30-4)
(8W-12-23)
8W - 47 - 2 8W-47 AUDIO SYSTEM NS/GS
J988W-3 GS004702
RADIO
LEFT
FRONT
(-)
C1 2
(+)
FRONT
LEFT
4 C2
(+)
REAR
LEFT
2 C2
(-)
REAR
LEFT
6 C2
RIGHT
REAR
(-)
RIGHT
REAR
(+)
C2 7 C2 3
(+)
FRONT
RIGHT
(-)
FRONT
RIGHT
5 C2 3 C1
2
3
SPEAKER
FRONT
LEFT LEFT
REAR
SPEAKER
6
3 3
2
SPEAKER
FRONT
RIGHT
3
6
SPEAKER
REAR
RIGHT
P34
B23
8 10 7 9
X55
20
BR/RD
X53
20
DG
X51
20
BR/YL
X51
20
BR/YL
X57
20
BR/LB
X57
20
BR/LB
X52
20
DB/WT
X52
20
DB/WT
X58
20
DB/OR
X58
20
DB/OR
X54
20
VT
X56
20
DB/RD
A9 A7 A10 A8
SPEAKER SPEAKER SPEAKER SPEAKER SPEAKER SPEAKER SPEAKER SPEAKER
NS/GS 8W-47 AUDIO SYSTEM
BASE
8W - 47 - 3
GS004703 J988W-3
C1
22
BLOCK
JUNCTION
85 87
30 86
2
C2
RUN-ACC A31
1
2
RADIO
CHOKE
X1
16
DG/RD
G300
8
Z1
14
BK
RADIO
C3
13
OUTPUT
12V
RADIO
1 C2
X60
20
RD/DG
X13
16
RD/DG
10A
FUSE
8
NAME
BRAND
SPEAKER
RELAY
5
LEFT
REAR
SPEAKER SPEAKER
REAR
RIGHT
5
BS03
X13
16
RD/DG
X13
16
RD/DG
5
RIGHT
DOOR
SPEAKER SPEAKER
DOOR
LEFT
5
RD/DG
16
X13 X13
16
RD/DG
14
B03
D01P
RD/DG
16
X13
RD/DG
16
X13
2
B01
D02
RADIO
CHOKE
OUTPUT
RADIO
CHOKE
OUTPUT
RADIO
CHOKE
OUTPUT
RADIO
CHOKE
OUTPUT
(8W-12-2)
(8W-10-16)
(8W-15-6)
(8W-12-11)
(8W-47-3)
(8W-47-5)
(8W-47-3)
(8W-47-5)
(8W-47-6)
(8W-47-7)
(8W-47-6)
(8W-47-7)
(8W-12-19)
8W - 47 - 4 8W-47 AUDIO SYSTEM
PREMIUM
NS/GS
J988W-3 GS004704
C2 6
RADIO
LEFT
REAR
(-)
2 3
SPEAKER
REAR
LEFT
6
A7 A9
2 C2
(+)
REAR
LEFT
3 6 2
A8 A10
C2 7 3 C2
RIGHT
REAR
(-) (+)
REAR
RIGHT
SPEAKER
REAR
RIGHT
7 9 10 8
2
1
SPEAKER
PILLAR
REAR
LEFT
RIGHT
REAR
PILLAR
SPEAKER
2
1
X57
20
BR/LB
X57
20
BR/LB
X157
20
BR/LB
X51
20
BR/YL
X51
20
BR/YL
X151
20
BR/YL
X52
20
DB/WT
X52
20
DB/WT
X152
20
DB/WT
X58
20
DB/OR
X58
20
DB/OR
X158
20
DB/OR
G202
P34
B23
11
A11
X15
16
BK/DG
BS08
BK/DG
16
X15
X15
16
BK/DG
X15
16
BK/DG
2
CHOKE
RADIO
5 4 1 5 4 1
X13
16
RD/DG
X13
16
RD/DG
X13
16
RD/DG
BS03
SPEAKER SPEAKER SPEAKER SPEAKER
RADIO
CHOKE
OUTPUT
(8W-15-5)
(8W-15-5)
(8W-47-4)
(8W-47-4)
PREMIUM
8W - 47 - 5
GS004705 J988W-3
C1 2
RADIO
LEFT
DOOR
(-)
5
2 3
SPEAKER
DOOR
LEFT
6
A14 A12
4 C2
(+)
DOOR
LEFT
3 6 2
5
A15 A13
C1 3 5 C2
RIGHT
DOOR
(-) (+)
DOOR
RIGHT
SPEAKER
DOOR
RIGHT
14 12 13 15
4
1
SPEAKER
PANEL
FRONT
LEFT RIGHT
FRONT
PANEL
SPEAKER
1
4
X13
16
RD/DG
X13
16
RD/DG
X55
20
BR/RD
X55
20
BR/RD
X155
20
BR/WT
X53
20
DG
X53
20
DG
X153
20
WT/BR
X54
20
VT
X54
20
VT
X156
20
VT/WT
X56
20
DB/RD
X56
20
DB/RD
X154
20
WT/VT
G202
P34
B23
11
A11
X15
16
BK/DG
BS08
BK/DG
16
X15
X15
16
BK/DG
X15
16
BK/DG
D02
B01
2
D01P
B03
14
RD/DG
16
X13
RD/DG
16
X13
1 1 D02
B01
D01P
B03
BS03
2
CHOKE
RADIO
B26
P18
B23 B6
D02
B120
7 3
1 4 4 1
5
10
B01
D02
B2 B23
P18
B25
X153
20
WT/BR
X155
20
BR/WT
25 2 6 26
X154
20
WT/VT
X156
20
VT/WT
X13
16
RD/DG
8 9 7 8
OUTPUT
RADIO
CHOKE
(8W-15-5)
(8W-15-5)
(8W-47-4)
(8W-47-4)
8W - 47 - 6 8W-47 AUDIO SYSTEM
PREMIUM LHD
NS/GS
J988W-3 GS004706
C1 3
RADIO
LEFT
DOOR
(-)
5
2 3
SPEAKER
DOOR
LEFT
6
A15 A13
5 C2
(+)
DOOR
LEFT
3 6 2
5
A14 A12
C1 2 4 C2
RIGHT
DOOR
(-) (+)
DOOR
RIGHT
SPEAKER
DOOR
RIGHT
145 13 12 14
4
1
SPEAKER
PANEL
FRONT
LEFT RIGHT
FRONT
PANEL
SPEAKER
1
4
X13
16
RD/DG
X13
16
RD/DG
X56
20
DB/RD
X56
20
DB/RD
X156
20
VT/WT
X53
20
VT
X54
20
VT
X154
20
WT/VT
X53
20
DG
X53
20
DG
X155
20
BR/WT
X55
20
BR/RD
X55
20
BR/RD
X153
20
WT/BR
G202
P34
B23
11
A11
X15
16
BK/DG
BS08
BK/DG
16
X15
X15
16
BK/DG
X15
16
BK/DG
D01P
B03
14
D02
B01
2
RD/DG
16
X13
RD/DG
16
X13
1 1 D02
B01
D01P
B03
BS03
2
CHOKE
RADIO
B25
P18
B23 B2
D02
B120
7 3
1 4 4 1
5
10
B01
D02
B6 B23
P18
B26
X154
20
WT/VT
X156
20
VT/WT
26 6 2 25
X153
20
WT/BR
X155
20
BR/WT
X13
16
RD/DG
8 9 7 8
RADIO
CHOKE
OUTPUT
(8W-15-5)
(8W-15-5)
(8W-47-4)
(8W-47-4)
PREMIUM RHD
8W - 47 - 7
GS004707 J988W-3
8W-48 WINDOW DEFOGGERS
Component Page
Dri ver Power Mi rror . . . . . . . . . . . . . . . . . . .8W-48-2
El ectri c Wi per De-I cer . . . . . . . . . . . . . . . . . .8W-48-3
Fuse 6 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . .8W-48-2
Fuse 7 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . .8W-48-2
Fuse 9 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . .8W-48-3
Fuse 12 (JB) . . . . . . . . . . . . . . . . . . . . . . . . .8W-48-2
Fuse 27 (PDC). . . . . . . . . . . . . . . . . . . . . . . .8W-48-2
G200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-48-2
Component Page
G400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-48-2
HVAC Control . . . . . . . . . . . . . . . . . . . . . .8W-48-2, 3
Juncti on Bl ock . . . . . . . . . . . . . . . . . . . . . .8W-48-2, 3
Message Center . . . . . . . . . . . . . . . . . . . . . . .8W-48-2
Passenger Power Mi rror . . . . . . . . . . . . . . . .8W-48-2
Rear Wi ndow Defogger . . . . . . . . . . . . . . . . .8W-48-2
Rear Wi ndow Defogger Rel ay . . . . . . . . . . . .8W-48-2
Rear Wi ndow Defogger Swi tch . . . . . . . . . . .8W-48-2
NS/GS 8W - 48 WINDOW DEFOGGERS 8W - 48 - 1
6
C1
10A
FUSE
12
85 87
30 86
REAR
WINDOW
DEFOGGER
RELAY
35 C1
20
C4 C4
32
27
FUSE
40A
A4
12
BK/RD
C14
22
WT/RD
A/C
HEATER
CONTROL
1 C1
FUSED
IGNITION
(RUN)
BK/LG
18
Z2
C1
21
7
FUSE
10A
C1
6
G200
5
REAR
WINDOW
DEFOGGER
SWITCH
ST-RUN A21 RUN A22
JUNCTION
BLOCK
6
FUSE
20A
14
C4
10 C1
RELAY
REAR
WINDOW
DEFOGGER
5
4
DEFOGGER
WINDOW
REAR
G400
5
4
5
REAR
WINDOW
DEFOGGER
SWITCH SENSE
7 6
C16
20
LB/YL
C16
20
LB/YL
L16
J03A
1
12
B17
LJ01
C15
12
BK/WT
Z1
12
BK
Z1
20
BK
Z1
20
BK
POWER
DISTRIBUTION
CENTER
10
CONTROL
CENTER
MESSAGE
V23
18
BR/PK
V23
18
BR/PK
BATT A0
HVAC
CONTROL
C1
C1
C1
C1
DRIVER
POWER
MIRROR
MIRROR
POWER
PASSENGER
FUSED
IGNITION
(ST-RUN)
(8W-12-12)
(8W-10-11)
(8W-10-14)
(8W-10-8)
(8W-12-10)
(8W-15-4)
(8W-10-16)
(8W-12-2)
(8W-12-9)
(8W-15-14)
(8W-10-8)
(8W-42-4)
(8W-46-3)
(8W-42-4)
(8W-62-2)
(8W-62-4)
(8W-62-2)
(8W-62-5)
8W - 48 - 2 8W-48 REAR WINDOW DEFOGGER NS/GS
J988W-3 GS004802
DE-ICER
WIPER
ELECTRIC
C1 7
CONTROL
HEATER
A/C
ELECTRIC
WIPER
DE-ICER
DRIVER
C66
18
BK/WT
HVAC
CONTROL
9
FUSE
15A
RUN-ACC A31
BLOCK
JUNCTION
15
C3
V20
18
RD
1
C2
1 C1
(8W-42-3)
(8W-42-3)
(8W-12-11)
(8W-12-2)
(8W-10-16)
NS/GS 8W-48 REAR WINDOW DEFOGGER 8W - 48 - 3
GS004803 J988W-3
8W-49 OVERHEAD CONSOLE
Component Page
Ambi ent Ai r Temperature Sensor . . . . . . . . .8W-49-2
BS05 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-49-2
BS06 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-49-2
Compass/Mi ni -Tri p Computer . . . . . . . . . . . .8W-49-2
CS02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-49-3
CS04 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-49-2
CS06 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-49-2, 3
Component Page
Fuse 6 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . .8W-49-2
Fuse 18 (PDC). . . . . . . . . . . . . . . . . . . . . . . .8W-49-3
G301 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-49-2, 3
Juncti on Bl ock . . . . . . . . . . . . . . . . . . . . . .8W-49-2, 3
Overhead Consol e . . . . . . . . . . . . . . . . . . .8W-49-2, 3
NS/GS 8W - 49 OVERHEAD CONSOLE 8W - 49 - 1
6
FUSE
20A
BLOCK
JUNCTION
ST-RUN A21
14
C1
4
OVERHEAD
CONSOLE
V23
18
BR/PK
CS04
3
Z2
18
BK/LG
FUSED
IGN.
(RUN)
GROUND (+)
BUS
CCD
6
5
G301
COMPASS/
MINI-TRIP
COMPUTER
11
V23
18
BR/PK
Z2
18
BK/LG
2
1
SENSOR
TEMPERATURE
AIR
AMBIENT
2
G32
20
BK/LB
10 8
B75
C20
5
G31
20
VT/LG
G31
20
VT/LG
G32
20
BK/LB
SENSOR
TEMPERATURE
AMBIENT SENSOR
GROUND
SIGNAL
D1
18
VT/BR
6
D1
18
VT/BR
PAIR
TWISTED
9
B75
C20
CS06
Z2
18
BK/LG
TO
BS05 BS06
TO
WT/BK
18
D2
B75
C20
5
WT/BK
18
D2
1
CCD
BUS
(-)
*3
*DIESEL
(8W-12-9)
(8W-12-2)
(8W-10-16)
(8W-12-9)
(8W-15-11)
(8W-49-3)
(8W-30-4)
(8W-30-31)
(8W-30-4)
(8W-30-31)
8W - 49 - 2 8W-49 OVERHEAD CONSOLE NS/GS
J988W-3 GS004902
18
FUSE
15A
BATT A0
CENTER
DISTRIBUTION
POWER
2
C2
BLOCK
JUNCTION
15 C2
19
C2
C1
1
JUNCTION
BLOCK
OVERHEAD
CONSOLE
COMPASS/
MINI-TRIP
COMPUTER
3
GROUND
2
B75
C20
CS02
17
C20
B75
LAMPS/
FRONT
READING
UNIVERSAL
GARAGE
DOOR
OPENER
(PART OF
SWITCH)
4 2
FUSED
B(+)
PANEL
LAMPS
FEED
GROUND
3
F41
20
PK/VT
F41
20
PK/VT
F41
20
PK/VT
Z2
18
BK/LG
CS06
Z2
18
BK/LG
Z2
18
BK/LG
Z2
18
BK/LG
E2
20
OR
E2
18
OR
9
B75
C20
G301
5
2
BODY
CONTROL
MODULE
* 3
* DIESEL
(8W-10-20)
(8W-10-8)
(8W-10-9)
(8W-12-2)
(8W-12-2)
(8W-10-20)
(8W-15-11)
(8W-15-12)
(8W-45-6)
NS/GS 8W-49 OVERHEAD CONSOLE 8W - 49 - 3
GS004903 J988W-3
8W-50 FRONT LIGHTING
Component Page
Body Control Modul e . . . . .8W-50-2, 9, 10, 11, 12, 13
BS15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-50-3, 6
BS16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-50-8
Combi nati on Fl asher/DRL
Modul e . . . . . . . . . . . . . . . . . . .8W-50-2, 11, 12, 13
Courtesy Lamp Rel ay . . . . . . . . . . . . . . .8W-50-9, 10
Dome Lamp Swi tch . . . . . . . . . . . . . . . . .8W-50-9, 10
Fog Lamp I ndi cator . . . . . . . . . . . . . . . . .8W-50-9, 10
Fog Lamp Rel ay . . . . . . . . . . . . . . . . . . . .8W-50-3, 5
Front Readi ng Lamps/Swi tch . . . . . . . . .8W-50-9, 10
Fuse 1 (JB) . . . . . . . . . . . . . . . . . . . . . .8W-50-11, 12
Fuse 3 (JB) . . . . . . . . . . . . . . . . . . . . . .8W-50-11, 12
Fuse 4 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . .8W-50-7
Fuse 4 (PDC). . . . . . . . . . . . . . . . . . .8W-50-2, 3, 5, 6
Fuse 5 (JB) . . . . . . . . . . . . . . . . . . . . . .8W-50-11, 12
Fuse 5 (PDC). . . . . . . . . . . . . . . . . . .8W-50-2, 3, 4, 6
Fuse 6 (PDC). . . . . . . . . . . . . . . . . . .8W-50-2, 3, 5, 6
Fuse 7 (PDC). . . . . . . . . . . . . . . . . . .8W-50-2, 3, 4, 6
Fuse 10 (PDC) . . . . . . . . . . . . . . . . . . . .8W-50-11, 12
Fuse 12 (JB) . . . . . . . . . . . . . . . . . . . . . . . .8W-50-13
Fuse 22 (PDC) . . . . . . . . . . . . . . . . . .8W-50-7, 11, 12
G200 . . . . . . . . . . . . . . . . . . . . . . . . . .8W-50-2, 8, 13
G300 . . . . . . . . . . . . . .8W-50-5, 6, 8, 9, 10, 11, 12, 13
G301. . . . . . . . . . . . . . . . . . . . . .8W-50-4, 6, 8, 11, 12
Headl amp Di mmer Swi tch. . . . . . . . . .8W-50-2, 5, 13
Headl amp Swi tch. . . . . . . . . . . . . . .8W-50-7, 8, 9, 10
Component Page
Hi gh Beam Rel ay . . . . . . . . . . . . . .8W-50-2, 3, 4, 5, 6
I gni ti on Swi tch . . . . . . . . . . . . . . . . . . . . . .8W-50-13
I l l umi nati on Lamp. . . . . . . . . . . . . . . . . .8W-50-9, 10
Juncti on Bl ock . . . . . .8W-50-2, 5, 7, 9, 10, 11, 12, 13
Left Fog Lamp . . . . . . . . . . . . . . . . . . . .8W-50-5, 6, 7
Left Front Park/Turn Si gnal Lamp . . . .8W-50-11, 12
Left Headl amp. . . . . . . . . . . . . . . . . . . . . .8W-50-3, 6
Left Headl amp Level i ng Motor . . . . . . . . . . .8W-50-8
Left Hi gh Headl amp . . . . . . . . . . . . . . . . .8W-50-3, 5
Left Low Headl amp. . . . . . . . . . . . . . . . . . . .8W-50-5
Low Beam Rel ay . . . . . . . . . . . . . .8W-50-2, 3, 4, 5, 6
Message Center . . . . . . . . . . . . . . . . . . . .8W-50-3, 13
Park Brake Swi tch . . . . . . . . . . . . . . . . . . .8W-50-13
Park Lamp Rel ay . . . . . . . . . . . . . . . .8W-50-7, 11, 12
Power Di stri buti on
Center. . . . . . . . . . . . .8W-50-2, 3, 4, 5, 6, 7, 11, 12
Radi o. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-50-10
Rear Fog Lamp I ndi cator . . . . . . . . . . . . . .8W-50-10
Ri ght Fog Lamp. . . . . . . . . . . . . . . . . . .8W-50-5, 6, 7
Ri ght Front Park/Turn Si gnal Lamp . . .8W-50-11, 12
Ri ght Headl amp . . . . . . . . . . . . . . . . . .8W-50-3, 6, 8
Ri ght Headl amp Level i ng Motor . . . . . . . . . .8W-50-8
Ri ght Hi gh Headl amp . . . . . . . . . . . . . . . .8W-50-3, 4
Ri ght Low Headl amp. . . . . . . . . . . . . . . . .8W-50-3, 4
Ri ght Rear Lamp Assembl y . . . . . . . . . . . . .8W-50-11
NS/GS 8W - 50 FRONT LIGHTING 8W - 50 - 1
85 87
30 86
HIGH
BEAM
RELAY
POWER
DISTRIBUTION
CENTER
BATT A0
RELAY
BEAM
LOW
87 85
10A
FUSE
5
10A
FUSE
4 7
FUSE
15A
6
FUSE
20A
C3
7 2
C3
P18
B23
20
B20 B21
21
L94
20
OR/WT
L94
20
OR/WT
L324
20
WT/LG
L324
22
WT/LG
9
10
8
12
HEADLAMP
DIMMER
G200
13
12
33 C3
15
BLOCK
JUNCTION
COMBINATION
FLASHER/
DRL
MODULE
MODULE
CONTROL
BODY
CONTROL
RELAY
BEAM
LOW
L93
22
PK
86 30
LOW
BEAM
SENSE
SWITCH
(PART OF
MULTI-
FUNCTION
SWITCH)
CHRYSLER
DODGE/
PYLMOUTH
C1 76
L193
20
OR/WT
Z1
18
BK
CONTROL
RELAY
BEAM
LOW
C5
8
C3
1
C5
1
C5
6
(8W-10-10)
(8W-10-8)
(8W-10-33)
(8W-10-34)
(8W-10-33)
(8W-10-34)
(8W-10-33)
(8W-10-34)
(8W-10-33)
(8W-10-34)
(8W-15-4)
(8W-12-2)
(8W-45-5)
8W - 50 - 2 8W-50 FRONT LIGHTING NS/GS
J988W-3 GS005002
85 87
30 86
6
C5
POWER
DISTRIBUTION
CENTER
C3
1
BATT A0
87 85
10A
FUSE
5
10A
FUSE
4 7
FUSE
15A
6
FUSE
20A
1
C5 C5
8
L44
20
VT/RD
L43
18
VT
L33
20
RD
L34
20
RD/OR
86 30
DODGE/
PYLMOUTH CHRYSLER CHRYSLER PYLMOUTH
DODGE/
CHRYSLER PYLMOUTH
DODGE/
CHRYSLER PYLMOUTH
DODGE/
TO
BS15 LEFT
HEADLAMP
TO TO
HEADLAMP
HIGH
LEFT
RIGHT
LOW
HEADLAMP
TO
TO
HEADLAMP
RIGHT
1
CENTER
MESSAGE
RIGHT
HEADLAMP
TO TO
HEADLAMP
HIGH
RIGHT
18
B23
P18
B18
L34
20
RD/OR
L34
20
RD/OR
L33
20
RD
L33
20
RD
L44
20
VT/RD
L44
20
VT/RD
L43
18
VT
L43
18
VT
L34
20
RD/OR
L34
20
RD/OR
LOW
BEAM
RELAY RELAY
BEAM
HIGH
FOG
LAMP
RELAY
(IN JB)
TO
FUSED
HIGH
BEAM
RELAY
OUTPUT
(8W-10-10)
(8W-10-8)
(8W-10-33) (8W-10-33) (8W-10-33) (8W-10-33)
(8W-50-6)
(8W-50-6)
(8W-50-5)
(8W-50-4)
(8W-50-6)
(8W-46-4)
(8W-50-6)
(8W-50-4)
(8W-50-2) (8W-50-2)
(8W-50-5)
NS/GS 8W-50 FRONT LIGHTING
8W - 50 - 3
GS005003 J988W-3
7
G301
B
A
HEADLAMP
HIGH
RIGHT RIGHT
LOW
HEADLAMP
A
B
L44
20
VT/RD
L34
20
RD/OR
Z1
20
BK
Z1
20
BK
BATT A0
30
87
15A
FUSE
7
LOW
BEAM
RELAY
1
C3 C5
6
RELAY
BEAM
HIGH
5
FUSE
10A
87
30
POWER
DISTRIBUTION
CENTER
(8W-15-10)
(8W-10-8)
(8W-10-33)
(8W-50-2) (8W-50-2)
(8W-10-33)
(8W-10-10)
8W - 50 - 4 8W-50 FRONT LIGHTING
NS/GS
J988W-3 GS005004
JUNCTION
BLOCK
FOG
LAMP
RELAY
85 87
30 86
16 C1
12
C1 C1
31
C1
25
2
1
LAMP
FOG
LEFT
RIGHT
FOG
LAMP
1
2
B19
A
(8W-50-6)
B
(8W-50-6)
HEADLAMP
SWITCH
TO TO
SWITCH
HEADLAMP
19 3
B3 B23
P18
L39
18
LB
L39
18
LB
Z39
20
BK
Z39
20
BK
Z39
18
BK
L39
18
LB
L39
18
LB
10
SWITCH)
FUNCTION
MULTI-
(PART OF
SWITCH
DIMMER
HEADLAMP
20
B20
L94
20
OR/WT
L94
20
OR/WT
LEFT
LOW
HEADLAMP
A
B
G300
9
B
A
HEADLAMP
HIGH
LEFT
1
Z1
20
BK
Z1
20
BK
L43
18
VT
L33
20
RD
CENTER
DISTRIBUTION
POWER
30
87
10A
FUSE
4
HIGH
BEAM
RELAY
1
C5 C5
8
RELAY
BEAM
LOW
6
FUSE
20A
87
30
BATT A0
L43
18
VT
LOW
BEAM
RELAY
CONTROL
(8W-12-2)
(8W-50-2)
(8W-15-8)
(8W-10-10)
(8W-10-33)
(8W-50-2) (8W-50-2)
(8W-10-33)
(8W-10-8)
(8W-50-9) (8W-50-9)
8W - 50 - 5
GS005005 J988W-3
LEFT
HEADLAMP
HEADLAMP
RIGHT
2
1 3
3 1
2
BS15
G300
9
LAMP
FOG
LEFT
2
1
L39
18
VT/RD
Z1
20
BK
1
2
RIGHT
FOG
LAMP
7
G301
L33
20
RD
L39
18
LB
L44
20
VT/RD
3
B3 B23
P18
L39
18
LB
VT/RD
18
L39
Z1
20
BK
L34
20
RD/OR
P18
B23 B19
19
Z39
20
BK
Z39
20
BK
Z39
18
BK
L43
18
VT
A
(8W-50-5)
B
(8W-50-5)
HEADLAMP
SWITCH
TO
TO
SWITCH
HEADLAMP
BATT A0
30
87
20A
FUSE
6
LOW
BEAM
RELAY
8
C5 C5
1
RELAY
BEAM
HIGH
4
FUSE
10A
87
30
POWER
DISTRIBUTION
CENTER
10A
FUSE
5 7
FUSE
15A
C5
6
C3
1
UP-EXPORT
EXCEPT BUILT-
-EXPORT
BUILT-UP
L43
18
VT
L43
18
VT
C
(8W-50-8)
TO
BS16
L44
20
VT/RD
L44
20
VT/RD
EXCEPT BUILT-
UP-EXPORT
BUILT-UP
-EXPORT
*2 *1
*3
D
(8W-50-8)
EXPORT
UP-
BUILT- EXCEPT
BUILT-UP-
EXPORT
RIGHT
HEADLAMP
TO
L34
20
RD/OR
L34
20
RD/OR
* BUILT-UP-EXPORT
(8W-15-8)
(8W-15-10)
(8W-10-8)
(8W-10-33)
(8W-10-34)
(8W-50-2) (8W-50-2)
(8W-10-33)
(8W-10-34)
(8W-10-10)
(8W-10-33)
(8W-10-34)
(8W-10-33)
(8W-10-34)
(8W-50-9)
(8W-50-9)
8W - 50 - 6 8W-50 FRONT LIGHTING NS/GS
J988W-3 GS005006
LAMP
FOG
LEFT
2
1 1
2
RIGHT
FOG
LAMP
P18
B23 B19
19
Z39
20
BK
Z39
20
BK
Z39
18
BK
C2 6
SWITCH
HEADLAMP
C1
3
BLOCK
JUNCTION
15A
FUSE
4
2 C1
F39
18
PK/LG
F39
18
PK/LG
C1
4
POWER
DISTRIBUTION
CENTER
PARK
LAMP
RELAY
BATT A0
L7
12
BK/YL
40A
FUSE
22
30
87
F
(8W-50-10)
HEADLAMP
SWITCH
TO
Z39 18BK
GROUND
(8W-50-10)
(8W-12-2)
(8W-12-8)
(8W-10-8)
(8W-50-11)
(8W-50-12)
(8W-10-8)
(8W-10-17)
BUILT-UP-EXPORT
8W - 50 - 7
GS005007 J988W-3
HEADLAMP
RIGHT
1 2
3
G300
BS16
7
G301
L44
20
VT/RD
L44
20
VT/RD
Z1
20
BK
3
1
VT/RD
20
L44
MOTOR
LEVELING
HEADLAMP
RIGHT LEFT
HEADLAMP
LEVELING
MOTOR
L44
20
VT/RD
P18
B23 B3
3
2 2
1
3
1
L44
20
VT/RD
L44
20
VT/RD
A16 P34
B23 16
L13
20
BR/YL
L13
20
BR/YL
L13
18
BR/YL
Z1
20
BK
Z1
20
BK
G200
9
Z1
20
BK
M M
C
(8W-50-6)
JUNCTION
BLOCK
FROM
SWITCH
HEADLAMP
2 C1
8
C1
1
C1
9
D
(8W-50-6)
FROM
CENTER
DISTRIBUTION
POWER
L34
20
RD/OR
(8W-15-8) (8W-15-10) (8W-15-4)
(8W-50-10)
BUILT-UP-EXPORT
NS/GS
J988W-3 GS005008
9 C1
C3
28
BLOCK
JUNCTION
HEADLAMP
SWITCH
85 87
30 86
34
C3
BATT F41
C1 11
C1
10
1
3
B75
C20
B22 P18
B23 22
SWITCH
LAMPS/
READING
FRONT
C1 3
10
C3
17
COURTESY
LAMP
RELAY
DRIVER
8
C2
SIGNAL
SWITCH
DIMMER
PANEL
LAMPS
DRIVER
2
23
C4
C2 1 12 C1
6
C1 C2
2
JUNCTION
BLOCK
29 C4
2
C2
G300
8
C4 21
BODY
CONTROL
MODULE
MODULE
CONTROL
BODY
8
C2 C2
3
0 4
HEADLAMP
SWITCH
SENSE
GROUND
10 C2 13 C2 C2 14
GROUND
SENSE
SWITCH
LAMP
PARK
C2 40
E2
20
OR
E92
22
OR/BK
M112
22
BR/LG
M111
22
BR/WT
M113
20
LB/PK
L307
20
LG/OR
L308
20
LG/WT
M13
20
BK/YL
M13
20
BK/YL
Z1
18
BK
Z1
20
BK
Z2
20
BK/LG
Z2
20
BK/LG
Z1
14
BK
LAMP
ILLUM.
INDIC.
LAMP
FOG
2 HEAD
3 AUTO
1 PARK
0 OFF
A
(8W-50-5)
B
(8W-50-5)
FROM
P18
P18
FROM
5 C2 C2 6
Z39
18
BK
L39
18
LB
3
2 1
0 0
1 2
3
4 ON
7
C2
C2 12
SWITCH
HEADLAMP
AUTO
L110
22
BK/YL
COURTESY
LAMP
RELAY
DOME
LAMP
SWITCH
4
C1
5
C1
C2 2
MODULE
CONTROL
BODY
11 C2
M32
22
BK/LB
E17
20
YL/BK
M13
20
BK/YL
D4
SENSE
FRONT
READING
LAMP
FEED
STEP
DIMMER
SWITCH
SENSE SENSE
SWITCH
LAMP
COURTESY
(8W-12-2)
(8W-10-20)
(8W-44-2)
(8W-12-2)
(8W-15-6)
(8W-45-3)
(8W-45-4)
(8W-45-5)
(8W-45-2)
(8W-45-4)
(8W-44-2)
(8W-45-4)
(8W-50-6)
(8W-50-6)
(8W-12-22)
(8W-12-23)
8W - 50 - 9
GS005009 J988W-3
9 C1
C3
28
BLOCK
JUNCTION
HEADLAMP
SWITCH
85 87
30 86
34
C3
BATT F41
C1 11
C1
10
1
3
B75
C20
B22 P18
B23 22
SWITCH
LAMPS/
READING
FRONT
C1 3
10
C3
17
COURTESY
LAMP
RELAY
DRIVER
8
C2
SIGNAL
SWITCH
DIMMER
PANEL
LAMPS
DRIVER
2
23
C4
C2 1 12 C1
6
C1 C2
2
JUNCTION
BLOCK
29 C4
2
C2
G300
8
C4 21
BODY
CONTROL
MODULE
MODULE
CONTROL
BODY
8
C2 C2
3
0 4
HEADLAMP
SWITCH
SENSE
13 C2
SENSE
SWITCH
LAMP
PARK
C2 40
E2
20
OR
E92
22
OR/BK
M112
22
BR/LG
M111
22
BR/WT
M113
20
LB/PK
L307
20
LG/OR
L308
20
LG/WT
M13
20
BK/YL
M13
20
BK/YL
Z1
18
BK
Z1
20
BK
Z1
14
BK
COURTESY
LAMP
RELAY
LAMP
ILLUM.
INDIC.
LAMP
FOG
3
2 1
0 0
1 2
3 0
1 2
3
REAR
FOG
LAMP
INDIC.
DOME
LAMP
SWITCH
C2
2
4 C1
5
C1
11 C2
STEP
SWITCH
DIMMER
C1 4
RADIO
STEP
DIMMER
SWITCH
SIGNAL
14
C2 C2
10
GROUND GROUND
M32
22
BK/LB
E17
20
YL/BK
0 OFF
1 PARK
3 REAR
2 HEAD
4 ON
SWITCH
LAMP
DOME
5 C2 6 C2
7
C2
Z2 20BK/LG
Z2 20BK/LG
D4
F
(8W-50-7)
FROM
P18 P18
FROM
E
(8W-50-11)
Z39
18
BK
L77
18
BR/YL
SENSE
FRONT
READING
LAMP
FEED
20YL/BK E17
(8W-12-2)
(8W-10-20)
(8W-44-2)
(8W-12-2)
(8W-15-5)
(8W-45-3)
(8W-45-4)
(8W-45-5)
(8W-45-2)
(8W-45-4)
(8W-47-2)
(8W-12-22)
(8W-12-22)
(8W-12-19)
(8W-12-23)
BUILT-UP-EXPORT
NS/GS
J988W-3 GS005010
C1
4
85 87
30 86
10
C3
1
FUSED
PARK LAMP
RELAY
OUTPUT
BODY
CONTROL
MODULE
POWER
DISTRIBUTION
CENTER
LAMP
LEFT
FRONT
PARK/
TURN
SIGNAL
2 1
3
3
1 2
SIGNAL
TURN
PARK/
FRONT
RIGHT
LAMP
C1
23
BLOCK
JUNCTION
16 1
FUSED
B(+)
C5
9
20A
FUSE
10
27 C2 2 C1 9 C2
G300
6
8
G301
L97
18
PK/DB
L7
12
BK/YL
L9
18
BK/WT
PARK
LAMP
RELAY
CONTROL
22
FUSE
40A
BATT A0
1
FUSE
10A 15A
FUSE
5 3
FUSE
15A
5
C1
5
C2
11
C2
Z1
18
BK
Z1
18
BK
L77
20
BR/YL
L61
18
LG
L78
20
DG/YL
L60
18
TN
SIGNAL
TURN
FRONT
RIGHT LEFT
FRONT
TURN
SIGNAL
4
ASSEMBLY
LAMP
REAR
RIGHT
L78
20
DG/YL
COMBINATION
FLASHER/
DRL
MODULE
PARK
LAMP
RELAY
2 3
*1 *3
*2
*3
*2
*3 *1
-EXPORT
BUILT-UP EXCEPT BUILT
-UP-EXPORT
BK
20
Z1
* BUILT-UP-EXPORT
E
(8W-50-10)
HEADLAMP
SWITCH
TO
L77
18
BR/YL
B28 B23
P18 28
L77
18
BR/YL
FUSED
B(+)
(8W-45-3)
(8W-10-8)
(8W-10-10)
(8W-12-2)
(8W-10-29)
(8W-15-7)
(8W-15-10)
(8W-10-17)
(8W-10-8)
(8W-12-8) (8W-12-8) (8W-12-8)
(8W-51-4)
(8W-51-5)
NS/GS 8W-50 FRONT LIGHTING 8W - 50 - 11
GS005011 J988W-3
C1
4
85 87
30 86
10
C3
1
FUSED
PARK LAMP
RELAY
OUTPUT
BODY
CONTROL
MODULE
POWER
DISTRIBUTION
CENTER
LAMP
LEFT
FRONT
PARK/
TURN
SIGNAL
2 1
3 3
1 2
SIGNAL
TURN
PARK/
FRONT
RIGHT
LAMP
C1
23
BLOCK
JUNCTION
16 1
C5
9
20A
FUSE
10
27 C2 2 C1 9 C2
G300
6 8
G301
L97
18
PK/DB
L7
12
BK/YL
L9
18
BK/WT
PARK
LAMP
RELAY
CONTROL
22
FUSE
40A
BATT A0
1
FUSE
10A 15A
FUSE
5 3
FUSE
15A
5
C1
5
C2
11
C2
Z1
20
BK
Z1
18
BK
L77
20
BR/YL
L61
18
LG
L78
20
DG/YL
L60
18
TN
SIGNAL
TURN
FRONT
RIGHT LEFT
FRONT
TURN
SIGNAL
COMBINATION
FLASHER/
DRL
MODULE
LAMP
RELAY
PARK
B (+)
FUSED
3 2
(8W-45-3)
(8W-10-8)
(8W-10-10)
(8W-12-2)
(8W-10-29)
(8W-15-7) (8W-15-10)
(8W-10-17)
(8W-10-8)
(8W-12-8) (8W-12-8) (8W-12-8)
DRL
NS/GS
J988W-3 GS005012
G300
6
4 ACC
0 OFF
3 LOCK
2 RUN
1 START
4
2
0
3
GY/BK
20
G9
GY/BK
20
G9
MESSAGE
CENTER
9
BK
20
Z1
PARK
BRAKE
SWITCH
14
G200
IGNITION
SWITCH
2 C1
1
C1
C3
8 9
C3
10
DRIVER
LAMP
WARNING
RED BRAKE
1
COMBINATION
FLASHER/
DRL
MODULE
11
10A
FUSE
12
2
BODY
CONTROL
MODULE
33 C3
9
SWITCH)
FUNCTION
MULTI-
(PART OF
SWITCH
DIMMER
HEADLAMP
L93
22
PK
RUN A22
6 12
HIGH/LOW
BEAM
RELAY
CONTROL
FUSED
IGNITION
(RUN)
GROUND
2
C2
Z1
14
BK G9
20
GY/BK
BLOCK
JUNCTION
(8W-15-7)
(8W-46-3)
(8W-15-4)
(8W-10-14)
(8W-12-12)
(8W-45-3)
(8W-50-2)
(8W-10-14)
(8W-12-2)
(8W-12-17)
DRL
8W - 50 - 13
GS005013 J988W-3
8W-51 REAR LIGHTING
Component Page
Back-Up Lamp . . . . . . . . . . . . . . . . . . . . .8W-51-4, 5
Back-Up Swi tch. . . . . . . . . . . . . . . . . . . . . . .8W-51-5
BS01 . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-51-4, 5, 7
BS02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-51-4, 5
Center Hi gh Mounted Stop Lamp . . . . . . . . .8W-51-7
Fuse 1 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . .8W-51-2
Fuse 3 (JB) . . . . . . . . . . . . . . . . . . . . . . . .8W-51-2, 6
Fuse 5 (JB) . . . . . . . . . . . . . . . . . . . . . . . .8W-51-2, 6
Fuse 10 (PDC). . . . . . . . . . . . . . . . . . . . . . . .8W-51-3
Fuse 12 (JB) . . . . . . . . . . . . . . . . . . . . .8W-51-3, 4, 5
Fuse 13 (PDC) . . . . . . . . . . . . . . . . . . . .8W-51-4, 5, 7
Fuse 22 (PDC). . . . . . . . . . . . . . . . . . . . . .8W-51-2, 6
G300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-51-2, 3
G301 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-51-3
G302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-51-4, 5
G400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-51-2, 7
Component Page
Headl amp Swi tch . . . . . . . . . . . . . . . . . . .8W-51-2, 6
Juncti on Bl ock . . . . . . . . . . . . . . . .8W-51-2, 3, 4, 5, 6
Left Rear Lamp Assembl y . . . . . . . . . . .8W-51-4, 5, 6
Li cense Lamp . . . . . . . . . . . . . . . . . . . . . . . .8W-51-2
Park Lamp Rel ay . . . . . . . . . . . . . . . . . . .8W-51-2, 6
Power Di stri buti on Center . . . . .8W-51-2, 3, 4, 5, 6, 7
Rear Fog Lamp . . . . . . . . . . . . . . . . . . . . . . .8W-51-6
Rear Fog Lamp I ndi cator . . . . . . . . . . . . . . .8W-51-6
Ri ght Front Park/Turn Si gnal Lamp . . . . . . .8W-51-2
Ri ght Rear Lamp Assembl y . . . . . . . . . .8W-51-4, 5, 6
Stop Lamp Swi tch . . . . . . . . . . . . . . . . .8W-51-4, 5, 7
Tai l /Stop Lamp . . . . . . . . . . . . . . . . . . . . .8W-51-4, 5
Tai l /Turn Si gnal Lamp . . . . . . . . . . . . . . .8W-51-4, 5
Transmi ssi on Range Sensor . . . . . . . . . . . . . .8W-51-4
NS/GS 8W - 51 REAR LIGHTING 8W - 51 - 1
C1
4
85 87
30 86
10
C3
40
PARK
LAMP
SWITCH
SENSE
BODY
CONTROL
MODULE
POWER
DISTRIBUTION
CENTER
BLOCK
JUNCTION
16
2 C1 9 C2
G300
8
L97
18
PK/DB
L7
12
BK/YL
22
FUSE
40A
BATT A0
15A
FUSE
5
C2
0
2
1
8
SWITCH
HEADLAMP
C2
3
FUSE
15A
1
2
LAMP
LICENSE
C1
23
1
FUSE
10A
1
PARK
LAMP
RELAY
5
B17
LJ01
6
J02A
L15
C1
18
PARK
LAMP
RELAY
CONTROL
FUSED
B(+)
L308
20
LG/WT
C2 2
21
C4
2
C2
Z1
18
BK
Z1
14
BK
TO
ASSEMBLY
LAMP
REAR
LEFT
TO
ASSEMBLY
LAMP
REAR
RIGHT
L77
20
BR/LB
L77
20
BR/LB
L78
20
DG/YL
L78
20
DG/YL
TURN
PARK/
FRONT
RIGHT
7
G400
Z1
20
BK
LAMP
SIGNAL
0 OFF
2 PARK
1 HEAD
2
*1
B
(8W-51-4)
A
(8W-51-4)
L77
20
BR/LB
* BUILT-UP-EXPORT
FUSED
B(+)
(8W-45-3)
(8W-45-4)
(8W-10-8)
(8W-12-2)
(8W-15-6)
(8W-10-17)
(8W-10-8)
(8W-12-8) (8W-12-8) (8W-12-8)
(8W-15-14)
(8W-50-11)
(8W-50-12)
(8W-50-9)
(8W-50-10)
(8W-51-5)
(8W-51-5)
(8W-12-19)
8W - 51 - 2 8W-51 REAR LIGHTING NS/GS
J988W-3 GS005102
10
FUSE
20A
BATT A0
POWER
DISTRIBUTION
CENTER
9
C5
L9
18
BK/WT
BLOCK
JUNCTION
27 C2
RUN A22
10A
FUSE
12
1 6
FUSED
B(+)
LEFT
REAR
TURN
SIGNAL
RIGHT
REAR
TURN
SIGNAL
FUSED
IGNITION
(RUN)
28
C2 C2
36
L63
18
DG/RD
2
1
(BUILT-UP
LAMP
REPEATER
LEFT
-EXPORT)
Z1
18
BK
14
G300
L63
18
DG/RD
C
(8W-51-4)
LEFT
REAR
LAMP
ASSEMBLY
TO TO
ASSEMBLY
LAMP
REAR
RIGHT
BR/RD
18
L62
G301
10
BK
18
Z1
-EXPORT)
RIGHT
REPEATER
LAMP
(BUILT-UP
1
2
BR/RD
18
L62
D
(8W-51-4)
4 5
COMBINATION
FLASHER/
DRL
MODULE
(8W-10-29)
(8W-10-8)
(8W-10-10)
(8W-12-2)
(8W-10-14)
(8W-12-12)
(8W-15-5) (8W-15-10)
(8W-51-5) (8W-51-5)
NS/GS 8W-51 REAR LIGHTING 8W - 51 - 3
GS005103 J988W-3
4
3
ASSEMBLY
LAMP
REAR
LEFT
TAIL/
TURN
SIGNAL
LAMP
TAIL/
STOP
LAMP
1 5
LAMP
BACK-UP BACK-UP
LAMP
1 5
LAMP
STOP
TAIL/
LAMP
SIGNAL
TURN
TAIL/
RIGHT
REAR
LAMP
ASSEMBLY
3
4
A
(8W-51-2)
B
(8W-51-2)
C
(8W-51-3)
D
(8W-51-3)
FROM
BLOCK
JUNCTION
JUNCTION
BLOCK
FROM
JUNCTION
BLOCK
FROM
JUNCTION
BLOCK
FROM
5
6
C3
8
POWER
DISTRIBUTION
CENTER
BATT A0
F32
18
PK/DB
6
1
20A
FUSE
13 12
FUSE
10A
18
C2
BLOCK
JUNCTION
BS01
BS02
R
L50
18
WT/TN
L50
18
WT/TN
L50
18
WT/TN
L63
18
DG/RD
L77
20
BR/LB
L78
20
DG/YL
L62
18
BR/RD
L1
20
VT/BK
L1
20
VT/BK
L1
20
VT/BK
RUN A22
F20
20
WT
F20
18
WT
E36
B33
5
6 6
9
G302
3
Z1
20
BK
Z1
20
BK
E36
B33
10
VT/BK
L1
18
TRANSMISSION
RANGE
SENSOR
STOP
LAMP
SWITCH
*5 *3 *6
*4 *1 *4 *1
*5 *3 *6
* BUILT-UP-EXPORT
(8W-10-10)
(8W-10-8)
(8W-10-29) (8W-12-12)
(8W-12-2)
(8W-70-2)
(8W-70-2)
(8W-10-14)
(8W-15-13)
(8W-31-3)
(8W-51-7)
8W - 51 - 4 8W-51 REAR LIGHTING
EATX
NS/GS
J988W-3 GS005104
4
3
ASSEMBLY
LAMP
REAR
LEFT
TAIL/
TURN
SIGNAL
LAMP
TAIL/
STOP
LAMP
1 5
LAMP
BACK-UP BACK-UP
LAMP
1 5
LAMP
STOP
TAIL/
LAMP
SIGNAL
TURN
TAIL/
RIGHT
REAR
LAMP
ASSEMBLY
3
4
A
(8W-51-2)
B
(8W-51-2)
C
(8W-51-3)
D
(8W-51-3)
FROM
BLOCK
JUNCTION
JUNCTION
BLOCK
FROM
JUNCTION
BLOCK
FROM
JUNCTION
BLOCK
FROM
5
6
C3
8
POWER
DISTRIBUTION
CENTER
BATT A0
F32
18
PK/DB
20A
FUSE
13
12
FUSE
10A
18
C2
BLOCK
JUNCTION
BS01
BS02
L50
18
WT/TN
L50
18
WT/TN
L50
18
WT/TN
L63
18
DG/RD
L77
20
BR/LB
L78
20
DG/YL
L62
18
BR/RD
L1
20
VT/BK
L1
20
VT/BK
L1
20
VT/BK
RUN A22
F20
20
WT
6 6
9
G302
3
Z1
20
BK
Z1
20
BK
STOP
LAMP
SWITCH
*5 *3 *6
*4 *1 *4 *1
*5 *3 *6
* BUILT-UP-EXPORT
BACK-UP
SWITCH
18
L1
VT/BK
10
B33
E120
2
1
WT
20
F20
5
B33
E120
DIESEL
BACK-UP
SWITCH
GAS
18
L1
VT/BK
10
B33
E36
5
B33
E36
WT
18
F20
1
2
(8W-10-10)
(8W-10-8)
(8W-10-29)
(8W-12-12)
(8W-12-2)
(8W-70-2)
(8W-70-2)
(8W-10-14)
(8W-15-13)
(8W-51-7)
NS/GS 8W-51 REAR LIGHTING
MTX
8W - 51 - 5
GS005105 J988W-3
C1
4
RELAY
LAMP
PARK
87
30
POWER
DISTRIBUTION
CENTER
BATT A0
40A
FUSE
22
5
FUSE
15A
BLOCK
JUNCTION
2 C1
L7
12
BK/YL
5
L77
18
BR/YL
B28 B23
P18 28
5 C2
SWITCH
HEADLAMP
0 OFF
1 PARK
2 HEAD
3 REAR
0
1 2
3
C2 2
REAR
FOG
LAMP
INDICATOR
7 C2
BLOCK
JUNCTION
C4 21
Z1
18
BK
3 4
BODY
CONTROL
MODULE
GROUND GROUND
B27 B23
P18 27
L36
20
LG
3
2
REAR
FOG
LAMP
ASSEMBLY
LAMP
REAR
LEFT
L36
20
LG
RIGHT
REAR
LAMP
ASSEMBLY
LAMP
FOG
REAR
2
3
L77
20
BR/LB
FROM
3 (JB)
FUSE
L78
20
DG/YL
L36
20
LG
C1 6
DIMMER
SWITCH
Z1 20BK
L77
18
BR/YL
C1 C1
18
(8W-50-11)
(8W-50-12)
(8W-10-8)
(8W-10-8)
(8W-10-17)
(8W-12-8)
(8W-12-2)
(8W-50-9)
(8W-12-2)
(8W-45-4)
(8W-12-8)
8W - 51 - 6 8W-51 REAR LIGHTING
BUILT-UP-EXPORT
NS/GS
J988W-3 GS005106
3
1
5
6
C3
8
POWER
DISTRIBUTION
CENTER
BATT A0
SWITCH
LAMP
STOP
F32
18
PK/DB
G400
2
CENTER
HIGH
MOUNTED
STOP
LAMP
Z1
20
BK
20A
FUSE
13
BS01
L50
18
WT/TN
L15
J02A
2
J01A
B17
2
L50
20
WT/TN
L50
18
WT/TN
L50
20
WT/TN
(8W-10-10)
(8W-10-8)
(8W-15-14)
(8W-10-29)
(8W-70-2)
NS/GS 8W-51 REAR LIGHTING 8W - 51 - 7
GS005107 J988W-3
8W-52 TURN SIGNALS
Component Page
Combi nati on Fl asher/DRL Modul e . . . . . .8W-52-2, 3
Fuse 10 (PDC). . . . . . . . . . . . . . . . . . . . . .8W-52-2, 3
Fuse 12 (JB) . . . . . . . . . . . . . . . . . . . . . . .8W-52-2, 3
G200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-52-2, 3
G300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-52-2, 3
G301 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-52-3
G302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-52-2, 3
Juncti on Bl ock . . . . . . . . . . . . . . . . . . . . . .8W-52-2, 3
Left Front Park/Turn Si gnal Lamp . . . . . . . .8W-52-2
Left Rear Lamp Assembl y . . . . . . . . . . . . . . .8W-52-2
Component Page
Left Turn I ndi cator . . . . . . . . . . . . . . . . . . . .8W-52-2
Message Center . . . . . . . . . . . . . . . . . . . . .8W-52-2, 3
Ri ght Rear Lamp Assembl y . . . . . . . . . . . . . .8W-52-3
Ri ght Turn I ndi cator . . . . . . . . . . . . . . . . . . .8W-52-3
Tai l /Turn Si gnal Lamp . . . . . . . . . . . . . . .8W-52-2, 3
Turn Si gnal /Hazard Swi tch . . . . . . . . . . . .8W-52-2, 3
NS/GS 8W - 52 TURN SIGNALS 8W - 52 - 1
DG/RD
18
L63
28
C2
REAR
SIGNAL
TURN
LEFT
BODY
CONTROL
MODULE
BK
18
Z1
COMBO
SWITCHED
GROUND
FLASHER TURN
SENSE
SIGNAL
LEFT
DB/PK
22
L91
L305
22
LB/WT
C3
26
C3
4
13
G200
TURN
SIGNAL/
HAZARD
SWITCH
JUNCTION
BLOCK
3
C4 36
Z1
20
BK
2
C2
G300
8
Z1
14
BK
LEFT
TURN
INDICATOR
LEFT
TURN
SIGNAL
FLASHER/
COMBINATION
MODULE
L63
18
DG/RD
REAR
2
21
C3
BLOCK
JUNCTION
19
DRL
BK
20
Z1
9
G302
LEFT
FRONT
TURN
SIGNAL
C2
11
3
1
L61
18
LG
LAMP
SIGNAL
TURN
PARK/
FRONT
LEFT
10
Z1
18
BK
FUSED
IGN.
(RUN)
BATT A0
POWER
DISTRIBUTION
CENTER
20A
FUSE
10
9
C5
C2 27
B (+)
FUSED
1
4 9 7 2
6
L9 18 BK/WT
12
FUSE
10A
RUN A22
(PART OF
MULTI-
FUNCTION
SWITCH)
1 HAZARD
2 LEFT
3 RIGHT
**3
**2
*3
*4
LEFT
REAR
LAMP
6
1
ASSEMBLY
LAMP
SIGNAL
TURN
TAIL/
2
1
LEFT
REPEATER
LAMP
(BUILT-UP
-EXPORT)
14
Z1
18
BK
* RHD
** BUILT-UP-EXPORT
L63
18
DG/RD
**5
**1
CENTER
MESSAGE
8
1
2 3
1 4
20
DB/PK
L91
5 P50
USED
NOT
(8W-45-5)
(8W-15-4)
(8W-12-2)
(8W-15-5)
(8W-15-6)
(8W-15-7)
(8W-12-2)
(8W-15-13)
(8W-50-11)
(8W-50-12)
(8W-10-8)
(8W-10-10)
(8W-10-29)
(8W-12-12)
(8W-10-14)
(8W-46-5)
(8W-51-4)
(8W-12-19)
8W - 52 - 2 8W-52 TURN SIGNALS NS/GS
J988W-3 GS005202
BR/RD
18
L62
36
C2
REAR
SIGNAL
TURN
RIGHT
BODY
CONTROL
MODULE
BK
18
Z1
COMBO
SWITCHED
GROUND
FLASHER TURN
SENSE
SIGNAL
RIGHT
13
G200
JUNCTION
BLOCK
3
C4 36
Z1
20
BK
2
C2
Z1
14
BK
RIGHT
TURN
INDICATOR
RIGHT
TURN
SIGNAL
FLASHER/
COMBINATION
MODULE
L62
18
BR/RD
REAR
4
14
C3
BLOCK
JUNCTION
21
DRL
BK
20
Z1
3
G302
RIGHT
FRONT
TURN
SIGNAL
C2
5
3
1
L60
18
TN
LAMP
SIGNAL
TURN
PARK/
FRONT
RIGHT
Z1
18
BK
FUSED
IGN.
(RUN)
BATT A0
POWER
DISTRIBUTION
CENTER
20A
FUSE
10
9
C5
C2 27
B (+)
FUSED
1
5 8 9 3
6
L9 18 BK/WT
12
FUSE
10A
RUN A22
**3
**2
*5
*4
RIGHT
REAR
LAMP
6
1
ASSEMBLY
LAMP
SIGNAL
TURN
TAIL/
2
1
RIGHT
REPEATER
LAMP
(BUILT-UP
-EXPORT)
Z1
18
BK
* RHD
** BUILT-UP-EXPORT
L62
18
BR/RD
G301
8
8
G300
G301
10
**1
**5
CENTER
MESSAGE
FUNCTION
SWITCH)
1 HAZARD
2 LEFT
3 RIGHT
DB/PK
22
L91
L302
22
LB/YL
C3
26
C3
22
TURN
SIGNAL/
HAZARD
SWITCH
(PART OF
MULTI-
8
1
2 3
1 3
20
DB/PK
L91
5 P50
USED
NOT
(8W-45-5)
(8W-15-4)
(8W-12-2)
(8W-12-2)
(8W-15-13)
(8W-50-11)
(8W-50-12)
(8W-10-8)
(8W-10-10)
(8W-10-29)
(8W-12-12)
(8W-10-14)
(8W-15-10)
(8W-15-6)
(8W-15-10)
(8W-46-5)
(8W-51-4)
(8W-12-19)
NS/GS 8W-52 TURN SIGNALS 8W - 52 - 3
GS005203 J988W-3
8W-53 WIPERS
Component Page
Body Control Modul e . . . . . . . . . . . . .8W-53-2, 3, 4, 5
Front Washer Motor . . . . . . . . . . . . . . .8W-53-3, 4, 5
Front Wi per Swi tch . . . . . . . . . . . . . . . .8W-53-2, 3, 5
Fuse 5 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . .8W-53-5
Fuse 6 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . .8W-53-4
Fuse 19 (PDC). . . . . . . . . . . . . . . . . . . . . .8W-53-2, 3
Fuse 22 (PDC). . . . . . . . . . . . . . . . . . . . . . . .8W-53-5
G200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-53-3, 4
G300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-53-2, 3
G301 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-53-3, 5
G400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-53-4
Headl amp Washer . . . . . . . . . . . . . . . . . . . . .8W-53-5
HVAC Control . . . . . . . . . . . . . . . . . . . . . . . .8W-53-4
Juncti on Bl ock . . . . . . . . . . . . . . . . . .8W-53-2, 3, 4, 5
Low Washer Fl ui d Swi tch . . . . . . . . . . . . . . .8W-53-3
Component Page
Park Lamp Rel ay . . . . . . . . . . . . . . . . . . . . .8W-53-5
Power Di stri buti on Center . . . . . . . . . . .8W-53-2, 3, 5
PTC 3 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . .8W-53-5
PTC 7 (JB). . . . . . . . . . . . . . . . . . . . .8W-53-2, 3, 4, 5
Rear Washer Motor . . . . . . . . . . . . . . . . . .8W-53-3, 4
Rear Washer Swi tch . . . . . . . . . . . . . . . . . . .8W-53-4
Rear Wi per Del ay On I ndi cator . . . . . . . . . . .8W-53-4
Rear Wi per Del ay Swi tch . . . . . . . . . . . . . . .8W-53-4
Rear Wi per Motor . . . . . . . . . . . . . . . . . . . . .8W-53-4
Rear Wi per On I ndi cator . . . . . . . . . . . . . . . .8W-53-4
Rear Wi per On Swi tch. . . . . . . . . . . . . . . . . .8W-53-4
Washer Modul e . . . . . . . . . . . . . . . . . . . . .8W-53-3, 5
Wi per Hi gh/Low Rel ay. . . . . . . . . . . . . . . .8W-53-2, 3
Wi per Modul e . . . . . . . . . . . . . . . . . . . . . . . .8W-53-2
Wi per On Rel ay . . . . . . . . . . . . . . . . . . . . .8W-53-2, 3
NS/GS 8W - 53 WIPERS 8W - 53 - 1
C5
7
30A
FUSE
19
BATT A0
POWER
DISTRIBUTION
CENTER
85
30 86
87A
87
87A
86 30
85 87
WIPER
ON
RELAY LOW
HIGH/
WIPER
RELAY
C4
2 5
C5 C5
4
C5
3
3 1
WIPER
MODULE
2
V4
12
RD/YL
V3
12
BR/WT
4
12
G300
Z1
14
BK
DG/WT
20
V7
BK
18
Z1
0 1
FRONT
WIPER
SWITCH
6
5
3
WT
20
V16
P18
B23 B1
V16
20
WT
41 C1 7 C2 C1 73
V52
20
DG/YL
V14
18
RD/VT
WIPER
ON/OFF
RELAY
CONTROL
FRONT
WIPER
SWITCH
WIPER
PARK
SWITCH
SENSE
MODULE
CONTROL
BODY
10
1 0
2
1
0 OFF
1 HIGH
3 WASH
2 LOW
7
7
PTC
9A
RUN-ACC A31
BLOCK
JUNCTION
5
C3
F1
20
DB
SWITCH)
FUNCTION
MULTI-
(PART OF
11 8
MUX
M
(8W-10-19)
(8W-10-8)
(8W-10-8)
(8W-15-5)
(8W-15-7)
(8W-45-3)
(8W-45-4)
(8W-12-16)
(8W-12-2)
(8W-10-16)
8W - 53 - 2 8W-53 WIPERS NS/GS
J988W-3 GS005302
BK/TN
20
G29
SIGNAL
FLUID
WASHER
LOW
58 C1
LOW
WASHER
FLUID
SWITCH
A
B
14
G301
Z1
20
BK
2
1 0
DB
20
F1
A
MOTOR
WASHER
REAR
FRONT
WASHER
MOTOR
DB
20
F1
BR
20
V10
BK
18
Z1
G200
13
B
A
POWER
DISTRIBUTION
CENTER
RELAY
LOW
HIGH/
WIPER
10
G300
C5
7
30A
FUSE
19
BATT A0
85
30 86
87A
87 86
85
WIPER
ON
RELAY
C4
2 5
C5
BK
18
Z1
0 1
FRONT
WIPER
SWITCH
5
3
WT
20
V16
P18
B23
1
V16
20
WT
C1 73
V14
18
RD/VT
WIPER
ON/OFF
RELAY
CONTROL
JUNCTION
BLOCK
BODY
CONTROL
MODULE
8 11
20
18 C3 C2 21
V10
20
BR
CONTROL
MOTOR
WASHER
FRONT
JUNCTION
BLOCK
RUN-ACC A31
PTC
7
9A
3
C2
30
B1
0 OFF
1 HIGH
2 LOW
3 WASH
SWITCH)
FUNCTION
MULTI-
(PART OF
7
6
WASHER
MODULE
(BUILT-
UP-EXPORT)
87 87A
31
FUSED
IGNITION
(RUN-ACC)
M
(8W-15-11)
(8W-53-4)
(8W-15-4)
(8W-10-8)
(8W-53-2)
(8W-15-7)
(8W-10-19)
(8W-10-8)
(8W-12-2)
(8W-45-3)
(8W-45-4)
(8W-12-2)
(8W-10-16)
(8W-12-16)
(8W-53-5)
NS/GS 8W-53 WIPERS 8W - 53 - 3
GS005303 J988W-3
BK/LG
18
Z2
G200
5
C1
21
INDICATOR
REAR
WIPER
DELAY
ON INDICATOR
ON
WIPER
REAR
DELAY
WIPER
REAR
SWITCH SWITCH
REAR
WIPER
ON SWITCH
WASHER
REAR
DRIVER
INDICATOR
ON
DELAY WIPER
ON
INDICATOR
DRIVER SWITCH
DELAY
WIPER
REAR REAR
WIPER
ON
SWITCH SENSE
SWITCH
WASHER
REAR
MUX
WASH
WIPE/
REAR
YL/WT
22
V26
C1 2
HVAC
CONTROL
BK
18
Z1
6
G400
L16
J03A 3
2
7
8 B17
LJ01
BR/LG
18
V13
BR/PK
18
V23
2
REAR
WIPER
MOTOR
M
1
3
49
C1
REAR
WIPER
MOTOR
DRIVER
BK/WT
20
V20
C2
38
REAR
MUX
WASH
WIPE/
CONTROL
MOTOR
WASHER
REAR
C1
50
7
C1
(ST-RUN)
IGN.
FUSED
12 11
6
FUSE
20A
ST-RUN A21
MODULE
CONTROL
BODY
C2
3
9A
7
PTC
RUN-ACC A31
BLOCK
JUNCTION
A
B
F1
20
DB
MOTOR
WASHER
REAR
FRONT
WASHER
MOTOR
A
F1
20
DB
CONTROL
HEATER
A/C
13
FUSED
IGNITION
(RUN-ACC)
PUMP
M
(8W-15-4)
(8W-42-3)
(8W-15-14)
(8W-12-9)
(8W-10-16)
(8W-45-2)
(8W-45-4)
(8W-45-6)
(8W-12-16)
(8W-10-16)
(8W-12-2)
(8W-53-3)
(8W-42-3)
8W - 53 - 4 8W-53 WIPERS NS/GS
J988W-3 GS005304
BLOCK
JUNCTION
22
FUSE
40A
BATT A0
CENTER
DISTRIBUTION
POWER
30
87
PARK
LAMP
RELAY
4
C1
2 C1
L7
12
BK/YL
RUN-ACC A31 BATT A2
9A
PTC
7 3
PTC
9A 15A
FUSE
5
LOGIC
20
BODY
CONTROL
MODULE
18
C3
21
C2
34
C1
11
V10
20
BR
BR
20
V10
MOTOR
WASHER
FRONT
B
V53
18
RD/YL
WASHER
HEADLAMP
WASHER
MODULE
B
A
11
Z1
18
BK
SWITCH)
FUNCTION
MULTI-
(PART OF
SWITCH
WIPER
FRONT
G301
31 30
S 56 P
FRONT
WASHER
MOTOR
CONTROL
WASHER
PUMP
CONTROL
SWITCH
OUTPUT
M
(8W-12-2)
(8W-10-17)
(8W-10-8)
(8W-10-8)
(8W-50-11)
(8W-10-16) (8W-10-13)
(8W-12-16) (8W-12-15) (8W-12-8)
(8W-45-4)
(8W-53-3)
(8W-53-3)
(8W-15-10)
NS/GS 8W-53 WIPERS
BUILT-UP-EXPORT
8W - 53 - 5
GS005305 J988W-3
8W-54 TRAILER TOW
Component Page
BS01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-54-3
Fuse 1 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . .8W-54-2
Fuse 3 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . .8W-54-2
Fuse 5 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . .8W-54-2
Fuse 22 (PDC). . . . . . . . . . . . . . . . . . . . . . . .8W-54-2
G302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-54-3
Juncti on Bl ock . . . . . . . . . . . . . . . . . . . . . . . .8W-54-2
Left Combi nati on Rel ay . . . . . . . . . . . . . . .8W-54-2, 3
Left Rear Lamp Assembl y . . . . . . . . . . . . .8W-54-2, 3
Component Page
Left Stop/Turn Si gnal Rel ay . . . . . . . . . . .8W-54-2, 3
Li cense Lamp . . . . . . . . . . . . . . . . . . . . . . . .8W-54-2
Park Lamp Rel ay . . . . . . . . . . . . . . . . . . . . .8W-54-2
Ri ght Combi nati on Rel ay . . . . . . . . . . . . .8W-54-2, 3
Ri ght Rear Lamp Assembl y . . . . . . . . . . . .8W-54-2, 3
Ri ght Stop/Turn Si gnal Rel ay . . . . . . . . . .8W-54-2, 3
Stop Lamp Swi tch . . . . . . . . . . . . . . . . . . . . .8W-54-3
Trai l er Tow Connector . . . . . . . . . . . . . . . .8W-54-2, 3
NS/GS 8W - 54 TRAILER TOW 8W - 54 - 1
C1
4
85 87
30 86
10
C3
BODY
CONTROL
MODULE
POWER
DISTRIBUTION
CENTER
BLOCK
JUNCTION
16
2 C1 9 C2
L97
18
PK/DB
L7
12
BK/YL
22
FUSE
40A
BATT A0
15A
FUSE
5
36
C2
SIGNAL
TURN
RIGHT LEFT
TURN
SIGNAL
3
FUSE
15A
2
C1
23
1
FUSE
10A
1
COMBINATION
FLASHER/
DRL
MODULE
PARK
LAMP
RELAY
C2
28
5
B17
J01A
6
J02A
L15
C1
18
PARK
LAMP
RELAY
CONTROL
L63
18
DG/RD
L77
20
BR/LB
L77
20
BR/LB
L62
18
BR/RD
L78
20
DG/YL
L78
20
DG/YL
2
BR/LB
20
L77
1 4
ASSEMBLY
LAMP
REAR
LEFT
4
ASSEMBLY
LAMP
REAR
RIGHT
1
1
4
1 RELAY
SIGNAL
TURN
STOP/
LEFT
LEFT
COMBINATION
RELAY
RELAY
COMBINATION
RIGHT
1
RIGHT
STOP/
TURN
SIGNAL
RELAY
4
2
TRAILER
TOW
CONNECTOR
L63
18
DG/RD
L63
18
DG/RD
L62
18
BR/RD
L62
18
BR/RD
L78
18
BR
L77
20
BR/LB
B99
T05
4
T08
B98 4 1
LAMP
SIGNAL
TURN
PARK/
FRONT
RIGHT
LAMP
LICENSE
FUSED
PARK
LAMP
RELAY
OUTPUT
*1
*5 *3
*5 *3
* BUILT-UP-EXPORT
4 5
LEFT
REAR
TURN
SIGNAL
FUSED
LEFT
INBOARD
TAIL
LAMP
RIGHT
TURN
SIGNAL
FUSED
B(+)
FUSED
B(+)
FUSED
LEFT
INBOARD
TAIL
LAMP
(8W-45-3)
(8W-10-8)
(8W-12-2)
(8W-10-17)
(8W-10-8)
(8W-12-8) (8W-12-8) (8W-12-8)
(8W-51-4)
(8W-51-5)
(8W-51-4)
(8W-51-5)
(8W-54-3)
(8W-54-3)
(8W-54-3)
(8W-54-3)
(8W-51-3)
(8W-50-11)
(8W-51-2)
8W - 54 - 2 8W-54 TRAILER TOW NS/GS
J988W-3 GS005402
RELAY
COMBINATION
LEFT RIGHT
COMBINATION
RELAY
4
3
4
3
3
5 1
LEFT
STOP/
TURN
SIGNAL
RELAY RELAY
SIGNAL
TURN
STOP/
RIGHT
5
3
1
3
G302
1 4
CONNECTOR
TOW
TRAILER
3
6
ASSEMBLY
LAMP
REAR
RIGHT
B98
T08
6
Z1
20
BK
Z1
20
BK
Z1
18
WT
L615
18
OR
L50
18
WT/TN
L50
18
WT/TN
L50
18
WT/TN
L605
18
DG
L73
18
YL
L74
18
LG
2
2
2
2
9
Z1
18
BK
Z1
18
BK
Z1
18
BK
Z1
18
BK
LEFT
REAR
LAMP
ASSEMBLY
6
6
T05
B99
Z1
20
BK
Z1
20
BK
STOP
LAMP
SWITCH
5
WT/TN
18
L50
L50
18
WT/TN
5
T05
B99
5
L50
18
WT/TN WT/TN
18
L50
WT/TN
18
L50
BS01
4 4
1 1
*6 *1 *1
* BUILT-UP-EXPORT
L50
18
WT/TN
5
B98
T08
5
*6
L50
18
WT/TN
STOP
LAMP
SWITCH
OUTPUT
STOP
LAMP
SWITCH
OUTPUT GROUND OUTPUT
SWITCH
LAMP
STOP
GROUND
(8W-15-13)
(8W-51-4)
(8W-51-5)
(8W-51-4)
(8W-51-5)
(8W-51-7)
(8W-70-2)
NS/GS 8W-54 TRAILER TOW 8W - 54 - 3
GS005403 J988W-3
8W-60 POWER WINDOWS
Component Page
Dri ver Power Wi ndow Swi tch . . . . . . . . . .8W-60-2, 3
Dri ver Wi ndow Motor . . . . . . . . . . . . . . . . . .8W-60-2
DS01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-60-2, 3
Express Down Modul e . . . . . . . . . . . . . . . . . .8W-60-2
G300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-60-2, 3
Juncti on Bl ock . . . . . . . . . . . . . . . . . . . . . .8W-60-2, 3
Component Page
Left Rear Vent Motor . . . . . . . . . . . . . . . . . .8W-60-2
Passenger Door Courtesy Lamp . . . . . . . . . .8W-60-3
Passenger Power Wi ndow Swi tch . . . . . . . . .8W-60-3
Passenger Wi ndow Motor . . . . . . . . . . . . . . .8W-60-3
PTC 8 (JB). . . . . . . . . . . . . . . . . . . . . . . . .8W-60-2, 3
PTC 9 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . .8W-60-2
Ri ght Rear Vent Motor . . . . . . . . . . . . . . . . .8W-60-2
NS/GS 8W - 60 POWER WINDOWS 8W - 60 - 1
6 8 13
2 1 2 1 4 3 4
14
SWITCH
WINDOW
POWER
DRIVER
3
EXPRESS
DOWN
MODULE
11 9
1 5 3 7
C2
17
BLOCK
JUNCTION
9A
8
PTC PTC
9
9A
RUN-ACC A31
34
C2
F21
16
TN
14
F21
16
TN TN/DG
14
F55
7
TN/DG
12
F55
2
BODY
CONTROL
MODULE
8
C1
PANEL
LAMPS
FEED
E2
20
OR
4
B02
D01D
1
SWITCH
LOCK
DOOR
DRIVER
E2
20
OR
E2
20
OR
G300
5
Z1
12
BK
DS01
B02
D01D 10
Z1
12
BK
1 2
M
MOTOR
WINDOW
DRIVER
Q21
16
WT
Q11
16
LG
DB
18
Q13
RD/WT
18
Q23
LEFT
REAR
VENT
MOTOR
3 2 1 2
MOTOR
VENT
REAR
RIGHT
Q14
18
GY
Q24
18
DG
13 2
8
1
M M
1 DOWN
2 UP
4 CLOSE
3 OPEN
(LHD) (LHD)
(RHD)
MOTOR
VENT
REAR
RIGHT
(RHD)
LEFT
REAR
VENT
MOTOR
*3 *1
* RHD
PANEL
LAMPS
FEED
(8W-12-2)
(8W-12-16) (8W-12-16)
(8W-10-16)
(8W-45-6)
(8W-61-2)
(8W-15-7)
(8W-15-7)
(8W-12-23)
8W - 60 - 2 8W-60 POWER WINDOWS NS/GS
J988W-3 GS006002
14 BR Q12 14 VT Q22
OR
20
E2
BK
18
Z1
5
D01P
B03
BK
20
Z1
11
2
PASSENGER
DOOR
COURTESY
LAMP
SWITCH
WINDOW
POWER
PASSENGER
7
1 2
M
MOTOR
WINDOW
PASSENGER
TN/DG
12
F55
12
B03
D01P
TN/DG
12
F55
BR/WT
12
Q16
BR/WT
14
Q16
D01P
B03
13
9
2
VT/WT
12
Q26
6
D01D
B02
VT/WT
14
Q26
6 2 1 3
1 2
8 5
RUN-ACC A31
D01P
B03
13
C2 C2
17
BLOCK
JUNCTION
9A
8
PTC
TN/DG
14
F55
7
TN/DG
12
F55
2
BODY
CONTROL
MODULE
8
C1
PANEL
LAMPS
FEED
E2
20
OR
11
B02
D01D
1
SWITCH
LOCK
DOOR
PASSENGER
E2
20
OR
G300
5
Z1
12
BK
DS01
B02
D01D
10
Z1
12
BK
2 4 13
2 1 2 1 4 3 4
SWITCH
WINDOW
POWER
DRIVER
3
EXPRESS
DOWN MODULE
9
1 DOWN
2 UP
3 OPEN
4 CLOSE
2 UP
1 DOWN
Z1 20BK
PANEL
FEED
LAMPS
GROUND
(8W-44-3)
(8W-10-16)
(8W-12-2)
(8W-12-16)
(8W-45-6)
(8W-61-2)
(8W-15-7)
(8W-15-7)
(8W-12-23)
NS/GS 8W-60 POWER WINDOWS 8W - 60 - 3
GS006003 J988W-3
8W-61 POWER DOOR LOCKS
Component Page
Body Control Modul e . . . . . . .8W-61-2, 3, 4, 5, 6, 7, 8
Door Lock Rel ay . . . . . . . . . . . . . . . .8W-61-3, 4, 7, 8
Door Unl ock Rel ay . . . . . . . . . . . . . . .8W-61-3, 4, 7, 8
Dri ver Door Lock Motor. . . . . . . . . . . . . . .8W-61-3, 7
Dri ver Door Lock Swi tch . . . . . . . . . . . . . .8W-61-2, 6
Dri ver Door Unl ock Rel ay . . . . . . . . . . . . .8W-61-7, 8
Dri ver Power Wi ndow Swi tch . . . . . . . . . .8W-61-2, 6
Fuse 28 (PDC). . . . . . . . . . . . . . . . . . . . . . . .8W-61-5
G200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-61-5
G300 . . . . . . . . . . . . . . . . . . . . . . . . .8W-61-3, 4, 7, 8
G301 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-61-2, 6
G400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-61-6
Juncti on Bl ock . . . . . . . . . . . .8W-61-2, 3, 4, 5, 6, 7, 8
Component Page
Left Rear Sl i di ng Door Contact . . . . .8W-61-3, 4, 7, 8
Left Rear Sl i di ng Door Lock Motor . . . . . .8W-61-4, 8
Li ftgate Lock Motor . . . . . . . . . . . . . .8W-61-3, 4, 7, 8
Passenger Door Lock Motor . . . . . . . .8W-61-3, 4, 7, 8
Passenger Door Lock Swi tch . . . . . . . . . . .8W-61-2, 6
Passenger Power Wi ndow Swi tch . . . . . . .8W-61-2, 6
PTC 3 (JB). . . . . . . . . . . . . . . . . . . . .8W-61-3, 4, 7, 8
Ri ght Rear Sl i di ng Door Contact . . . .8W-61-3, 4, 7, 8
Ri ght Rear Sl i di ng Door Lock Motor . . . . .8W-61-4, 8
NS/GS 8W - 61 POWER DOOR LOCKS 8W - 61 - 1
C1
8
2
BODY
CONTROL
MODULE
PANEL
LAMPS
FEED
BLOCK
JUNCTION
PASSENGER
DOOR
SWITCH
MUX
55
C1
C1
45
MUX
SWITCH
DOOR
DRIVER
2
3
1
3
1 2
DRIVER
DOOR
LOCK
SWITCH
3
G301
2
Z2
20
BK/LG
B02
D01D
3 3
D01P
B03
BK/LG
20
Z2
Z2
20
BK/LG
Z2
20
BK/LG
P97
20
WT/DG
11
P97
20
WT/DG
WT/LG
20
P96
D01P
B03
4
WT/LG
20
P96
D01D
B02
4
11
E2
20
OR
E2
20
OR
SWITCH
WINDOW
POWER
DRIVER
PASSENGER
POWER
WINDOW
SWITCH
E2
20
OR
E2
20
OR
6
14
E2
20
OR
E2
20
OR
SWITCH
LOCK
DOOR
PASSENGER
PANEL
LAMP
FEED
PANEL
LAMP
FEED
(8W-45-8)
(8W-12-2)
(8W-15-10)
(8W-15-11)
(8W-15-12)
(8W-60-2)
(8W-60-3)
(8W-12-23)
8W - 61 - 2 8W-61 POWER DOOR LOCKS
STANDARD
NS/GS
J988W-3 GS006102
BR/RD
20
F133
TO
SLIDING
REAR
RIGHT
DOOR
CONTACT
VT/WT
20
F136
VT/WT
20
F136
L15
J02A
4
LJ01
B17
9
BR/RD
20
F133
5
J02A
L15
10
B17
LJ01
CONTACT
DOOR
LEFT
REAR
SLIDING
TO
9
D01P
B03
BR
20
F133
BR
20
F133
VT/WT
20
F136
3
1
VT/YL
20
F136
VT/YL
20
F136
BK/PK
20
F131
5
BK/PK
20
F131
D01D
B02
12 D01P
B03
10
BR
20
F133
BR
20
F133
Z1
14
BK
8
G300
2
1
11
C1 C1
15
C1
19
C1
9
C1
32
DRIVER
DOOR
LOCK
MOTOR
1
2
DOOR
UNLOCK
RELAY
CONTROL CONTROL
RELAY
LOCK
DOOR
6
MODULE
CONTROL
BODY
8
C2
2
87A 86 87
85 30
DOOR
LOCK
RELAY RELAY
UNLOCK
DOOR
JUNCTION
BLOCK
30 85
87 86 87A
M
M
M
MOTOR
LOCK
LIFTGATE
BATT A2
9A
PTC
3
F136
20
VT/WT
MOTOR
LOCK
DOOR
PASSENGER
(8W-61-4)
(8W-61-4)
(8W-15-6)
(8W-45-7)
(8W-12-2)
(8W-10-13)
(8W-12-14)
(8W-12-15)
(8W-10-13)
NS/GS 8W-61 POWER DOOR LOCKS
STANDARD
8W - 61 - 3
GS006103 J988W-3
LEFT
REAR
SLIDING
DOOR
CONTACT CONTACT
DOOR
SLIDING
REAR
RIGHT RIGHT
REAR
SLIDING
DOOR
CONTACT CONTACT
DOOR
SLIDING
REAR
LEFT
BR/YL
20
F133
19
C1
MOTOR
PASSENGER
DOOR
LOCK
TO
F136
20
VT/YL
MOTOR
LOCK
LEFT
REAR
SLIDING
DOOR
F136
20
VT/WT
TO
MOTOR
LOCK
LIFTGATE
F133
20
BR/YL
DOOR
SLIDING
REAR
RIGHT
LOCK
MOTOR
BATT A2
2
C2
G300
8
BK
14
Z1
C1
26 15
C1
85 30
BLOCK
JUNCTION
DOOR
UNLOCK
RELAY RELAY
LOCK
DOOR
30 85
8
BODY
CONTROL
MODULE
6
DOOR
LOCK
RELAY
CONTROL CONTROL
RELAY
UNLOCK
DOOR
M M
2 2 1 1
86 87 87A 86 87 87A
9A
PTC
3
VT/WT
20
F136
VT/YL
20
F136
15
C20
B75
(8W-61-3)
(8W-61-3)
(8W-10-13)
(8W-15-6)
(8W-12-2)
(8W-45-7)
(8W-12-14)
(8W-12-15)
(8W-10-13)
STANDARD
NS/GS
J988W-3 GS006104
INTERFACE
RKE
C1
19
B (+)
FUSED
BK/LG
20
Z2
11
G200
LG/RD
20
G96
LG/RD
20
G96
LG/RD
20
G96
23 P34
B23
GROUND
6
RKE
INTERFACE
C2
1
RKE
INTERFACE
GY/BK
22
D9
ENABLE
PROGRAM
RKE MODULE
5
37
C2
PK
20
M1
PK
20
M1
B (+)
FUSED
REMOTE
KEYLESS
ENTRY
MODULE
4
3
MEMORY
SEAT/
MIRROR
MODULE
16 C1
C4
6
PK
20
M1
C1 13
MODULE
CONTROL
BODY
9
FUSED
B (+)
JUNCTION
BLOCK
CENTER
DISTRIBUTION
POWER
BATT A0
28
FUSE
10A
5
C3
A23
M1
22
PK
7
P50
USED
NOT
RKE MODULE
PROGRAM
ENABLE
(8W-15-4)
(8W-62-3)
(8W-45-6)
(8W-12-2)
(8W-10-9)
(8W-10-8)
(8W-10-11)
(8W-12-20)
RKE
8W - 61 - 5
GS006105 J988W-3
6
J03A
L16
6
B17
LJ01
WT/RD
20
P98
WT/RD
20
P98
BK/LG
20
Z2
9
G400
WT/RD
20
P98
C1
MUX
LOCK/UNLOCK
LIFTGATE
44
(VTSS)
2
1
SWITCH
DISARM
ARM/
LIFTGATE
6
E2
20
OR
C1
8
2
BODY
CONTROL
MODULE
PANEL
LAMPS
DRIVER
BLOCK
JUNCTION
PASSENGER
DOOR
SWITCH
MUX
55
C1
C1
45
MUX
SWITCH
DOOR
DRIVER
2
3
1
3
1 2
DRIVER
DOOR
LOCK
SWITCH
3
G301
2
Z2
20
BK/LG
B02
D01D
3 3
D01P
B03
BK/LG
20
Z2
Z2
20
BK/LG
Z2
20
BK/LG
P97
20
WT/DG
11
P97
20
WT/DG
WT/LG
20
P96
D01P
B03
4
WT/LG
20
P96
D01D
B02
4 11
E2
20
OR
E2
20
OR
14
SWITCH
WINDOW
POWER
DRIVER
PASSENGER
POWER
WINDOW
SWITCH
E2
20
OR
E2
20
OR
E2
20
OR
PASSENGER
DOOR
ARM/
DISARM
SWITCH
1
2
(VTSS)
P96
20
WT/LG
Z2
20
BK/LG
(VTSS)
2
1
SWITCH
DISARM
ARM/
DOOR
DRIVER
Z2
20
BK/LG
P97
20
WT/DG
SWITCH
LOCK
DOOR
PASSENGER
PANEL
FEED
LAMPS
PANEL
FEED
LAMPS
(8W-15-14)
(8W-45-8)
(8W-12-2)
(8W-15-10)
(8W-15-11)
(8W-15-12)
(8W-60-2)
(8W-60-3)
(8W-12-23)
RKE
NS/GS
J988W-3 GS006106
BR/RD
20
F133
TO
SLIDING
REAR
RIGHT
DOOR
CONTACT
VT/WT
20
F136
VT/WT
20
F136
L15
J02A
4
LJ01
B17
9
BR/RD
20
F133
5
J02A
L15
10
B17
LJ01
CONTACT
DOOR
LEFT
REAR
SLIDING
TO
9
D01P
B03
BR
20
F133
BR
20
F133
VT/WT
20
F136
3
1
VT/YL
20
F136
VT/YL
20
F136
BK/PK
20
F131
5
BK/PK
20
F131
D01D
B02
12 D01P
B03
10
BR
20
F133
BR
20
F133
Z1
14
BK
8
G300
2
1
11
C1 C1
15
C1
19
C1
9
C1
32
DRIVER
DOOR
LOCK
MOTOR
1
2
DOOR
UNLOCK
RELAY
CONTROL CONTROL
UNLOCK
FRONT
LEFT
6
MODULE
CONTROL
BODY
5
C2
2
87A 86 87
85 30
DOOR
LOCK
RELAY RELAY
UNLOCK
DOOR
JUNCTION
BLOCK
BATT A2
30 85
87 86 87A
DRIVER
DOOR
UNLOCK
RELAY
8
DOOR
LOCK
RELAY
CONTROL
87A 87 86
30 85
M
M
M
3
PTC
9A
MOTOR
LOCK
LIFTGATE
F136
20
VT/WT
MOTOR
LOCK
DOOR
PASSENGER
16
C20
B75
(8W-61-8)
(8W-61-8)
(8W-15-6)
(8W-45-7)
(8W-10-8)
(8W-12-2)
(8W-12-14)
(8W-12-15)
(8W-12-19)
(8W-10-13)
RKE
8W - 61 - 7
GS006107 J988W-3
DOOR
UNLOCK
RELAY
CONTROL CONTROL
UNLOCK
FRONT
LEFT
6
MODULE
CONTROL
BODY
5
85 30
DOOR
LOCK
RELAY RELAY
UNLOCK
DOOR
30 85
DRIVER
DOOR
UNLOCK
RELAY
8
DOOR
LOCK
RELAY
CONTROL
30 85
JUNCTION
BLOCK
C1
15 26
C1
Z1
14
BK
8
G300
C2
2
BATT A2
MOTOR
LOCK
RIGHT
REAR
SLIDING
DOOR
BR/YL
20
F133
LIFTGATE
LOCK
MOTOR
TO
VT/WT
20
F136
DOOR
SLIDING
REAR
LEFT
LOCK
MOTOR
VT/YL
20
F136
TO
LOCK
DOOR
PASSENGER
MOTOR
C1
19
F133
20
BR/YL
LEFT
REAR
SLIDING
DOOR
CONTACT CONTACT
DOOR
SLIDING
REAR
RIGHT RIGHT
REAR
SLIDING
DOOR
CONTACT CONTACT
DOOR
SLIDING
REAR
LEFT
M M
2 2 1 1
86 87 87A 87A 87A 87 87 86 86
5
J02A
L15
LJ01
B17
10
F136
20
VT/WT
C20
B75
16
F136
20
VT/YL
9
B03
D01P
F136
20
VT/YL
15
B75
C20
F133
20
BR/YL
9A
PTC
3
(8W-45-7)
(8W-12-2)
(8W-15-6)
(8W-10-13)
(8W-61-7)
(8W-61-7)
(8W-12-14)
(8W-12-15)
(8W-12-19)
(8W-10-13)
RKE
NS/GS
J988W-3 GS006108
8W-62 POWER MIRRORS
Component Page
Body Control Modul e . . . . . . . . . . .8W-62-2, 3, 4, 5, 8
Dri ver Power Mi rror . . . . . . . . . . .8W-62-2, 4, 6, 7, 8
DS01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-62-3
Fuse 18 (PDC) . . . . . . . . . . . . . . . . . . . .8W-62-2, 4, 8
Fuse 28 (PDC). . . . . . . . . . . . . . . . . . . . . . . .8W-62-3
G300 . . . . . . . . . . . . . . . . . . . . . . .8W-62-2, 3, 4, 5, 8
Juncti on Bl ock . . . . . . . . . . . . . . . .8W-62-2, 3, 4, 5, 8
Memory Power Seat Swi tch. . . . . . . . . . . . . .8W-62-3
Memory Seat/Mi rror Modul e . . . . .8W-62-3, 4, 5, 6, 7
Memory Set Swi tch . . . . . . . . . . . . . . . . . . . .8W-62-3
Component Page
Passenger Power Mi rror . . . . . . . . . . . .8W-62-2, 5, 8
Passenger Power Seat Swi tch . . . . . . . . . . . .8W-62-3
Power Fol di ng Mi rror Swi tch . . . . . . . . . . . .8W-62-8
Power Mi rror Fol d Rel ay . . . . . . . . . . . . . . . .8W-62-8
Power Mi rror Swi tch . . . . . . . . . . . . . . .8W-62-2, 4, 5
Power Mi rror Unfol d Rel ay . . . . . . . . . . . . . .8W-62-8
Power Seat Ci rcui t Breaker . . . . . . . . . . . . . .8W-62-3
NS/GS 8W - 62 POWER MIRRORS 8W - 62 - 1
BATT A0
OR
20
E2
5
YL
20
P71
DB/WT
20
P75
YL/PK
20
P73
WT
20
P70
YL/BK
20
P72
DB
20
P74
13 7 12 6 1 8
4 3 3 4 3 4
5 6
1 2 1 2 2 1
MIRROR
POWER
DRIVER
3 1 2
PASSENGER
POWER
MIRROR
3
M M
1 2
11
BK
20
Z1
SWITCH
MIRROR
POWER
9
G300
8
35 C4
2
C2
BLOCK
JUNCTION
Z1
14
BK
JUNCTION
BLOCK
2
BODY
CONTROL
MODULE PANEL
LAMPS
FEED
2
18
FUSE
15A
POWER
DISTRIBUTION
CENTER
C2
16
C3
15 C2
F41
20
PK/VT
F41
20
PK/VT
M M
C1 C1 C1 C1 C1 C1
6 RIGHT MIRROR
1 LEFT
2 RIGHT
4 DOWN
3 UP
5 LEFT MIRROR
1
C4
C1 4
C1
5 5
C1
C1 4
(8W-10-8)
(8W-15-6)
(8W-12-2)
(8W-12-2)
(8W-45-5)
(8W-10-20)
(8W-10-9)
(8W-12-23)
(8W-12-21)
(8W-12-19)
8W - 62 - 2 8W-62 POWER MIRRORS
STANDARD
NS/GS
J988W-3 GS006202
C3
CENTER
DISTRIBUTION
POWER
10A
FUSE
28
5
BATT A0
13 C1
JUNCTION
BLOCK
M1
20
PK
MODULE
MIRROR
SEAT/
MEMORY
16 C1
FUSED
B (+)
M1
20
PK
BATT A2
B (+)
FUSED
C2 8
F35
14
RD
5
F35
14
RD
F35
14
RD
F35
14
RD
3
S02
B09
3
B56
S02
PASSENGER
POWER
SEAT
SWITCH
5 6 4
3
1 2 3
MEMORY
SET
SWITCH
C1
8 20
C1
21
C1
MEMORY
SET NO. 1
MEMORY
NO. 2
MEMORY
P22
20
PK/BK
4
P22
20
PK/BK PK/RD
20
P23
6
PK/RD
20
P23 P24
20
PK/WT
7
B01
D02D
P24
20
PK/WT
GROUND
C2
7
5
G300
2
Z1
14
BK
B09
S02
1
Z1
12
BK
1
Z1
20
BK
SWITCH
SEAT
POWER
MEMORY
Z1
20
BK
DS01
Z1
12
BK
B02
D01D
10
INTERFACE
RKE
19
C1
6 1 C2
MODULE
ENTRY
KEYLESS
REMOTE BODY
CONTROL
MODULE
G96
20
LG/RD
23
B23
P34
G96
20
LG/RD
G96
20
LG/RD
RKE
INTER-
FACE FACE
INTER-
RKE
A23
1 SET
2 MEM 1
3 MEM 2
FUSED
B (+)
B (+)
FUSED
GROUND
POWER
SEAT
CIRCUIT
BREAKER
30A
(8W-10-9)
(8W-10-11)
(8W-10-8)
(8W-12-2)
(8W-10-13)
(8W-63-3)
(8W-15-5)
(8W-15-7)
(8W-63-5)
(8W-15-7)
(8W-61-5)
(8W-45-6)
NS/GS 8W-62 POWER MIRRORS
MEMORY
8W - 62 - 3
GS006203 J988W-3
DB/WT
20
P75
YL
20
P71
15
P18
B23
8
C1
12 11
C1
LEFT
MIRROR
HORIZONTAL VERTICAL
MIRROR
LEFT
10 P18
B23
YL/PK
20
P73
COMMON
MIRROR
LEFT
LEFT
MIRROR
HORIZONTAL
POSITION
LEFT
MIRROR
POSITION
GROUND POSITION
VERTICAL
MIRROR
LEFT
P65
20
DB/YL
26
P69
20
WT/RD
28
P34
B23
27
YL/OR
20
P64
C1
3
C1
1
MEMORY
SEAT/
MIRROR
MODULE
10 C1
2
C1
C2 3 C2 2 1 C2 C1 C1 C1
PK/VT
20
F41
PK/VT
20
F41
C2
CENTER
DISTRIBUTION
POWER
15A
FUSE
18
2
FEED
LAMPS
PANEL
2
BK
14
Z1
JUNCTION
BLOCK
C2
2
C4 35
8
G300
9
POWER
MIRROR
SWITCH
Z1
20
BK
11
2 1 3
1 2 2 1 2 1
6 5
4 3 4 3 3 4
6 12 7
P73
20
YL/PK
5
E2
20
OR
BATT A0
JUNCTION
BLOCK
BODY
CONTROL
MODULE
16
C3
15
C2
A26 A28 A27
B8 B15
B10
M M
6 RIGHT MIRROR
1 LEFT
2 RIGHT
4 DOWN
3 UP
5 LEFT MIRROR
C4
1
P73
20
YL/PK
DRIVER
POWER
MIRROR
P71
20
YL
P75
20
DB/WT
8 13 1
C1 4
C1
5
(8W-10-9)
(8W-10-20)
(8W-12-2)
(8W-15-6)
(8W-10-8)
(8W-12-2)
(8W-45-5)
(8W-12-23)
(8W-12-19)
MEMORY
NS/GS
J988W-3 GS006204
WT
20
P70
WT
20
P70
YL/BK
20
P72
YL/BK
20
P72
DB
20
P74
DB
20
P74
HORIZ.
MIRROR
RIGHT
B23
P18
11
C1 25
P74
20
DB YL/BK
20
P72
VERTICAL
MIRROR
RIGHT
24 C1
9
BATT F41
5
13 1 8
4 3 3 4 3 4
5 6
1 2 1 2 2 1
MIRROR
POWER
PASSENGER
1 3 2
M M
11
BK
20
Z1
SWITCH
MIRROR
POWER
G300
8
35 C4
2
C2
BLOCK
JUNCTION
Z1
14
BK
2
PANEL
LAMPS
FEED
C1 C1 C1 C2 1 2 C2 3 C2
C1
14
C1 23
MODULE
MIRROR
SEAT/
MEMORY
13
C1
15
C1
P67
20
YL/RD
30
B23
P34
25
WT/BK
20
P66
29
DG/RD
20
P68
RIGHT
MIRROR
VERTICAL
POSITION
GROUND
POSITION
MIRROR
RIGHT
HORIZONTAL
MIRROR
RIGHT
RIGHT
MIRROR
COMMON
P70
20
WT
7
JUNCTION
BLOCK
BODY
CONTROL
MODULE
E2 20 OR
B7 B9 B11
A30 A25 A29
1 LEFT
2 RIGHT
3 UP
4 DOWN
5 LEFT MIRROR
6 RIGHT MIRROR
1
C4
6 7 12
POSITION
C1 4
C1
5
(8W-10-20)
(8W-15-6)
(8W-12-2)
(8W-12-2)
(8W-45-5)
(8W-12-23)
(8W-12-19)
MEMORY
8W - 62 - 5
GS006205 J988W-3
M M
B15 B8 A27 A28 A26
YL/PK
20
P73
MIRROR
POWER
DRIVER
3 1 2 C1 C1 C1 C2 1 2 C2 3 C2
C1
2
C1 10
MODULE
MIRROR
SEAT/
MEMORY
1
C1
3
C1
P64
20
YL/OR
27
B23
P34
28
WT/RD
20
P69
26
DB/YL
20
P65
LEFT
MIRROR
VERTICAL
POSITION
GROUND
POSITION
MIRROR
LEFT
POSITION
HORIZONTAL
MIRROR
LEFT
LEFT
MIRROR
COMMON
LEFT
MIRROR
VERTICAL HORIZONTAL
MIRROR
LEFT
C1
11 12
C1
8
B23
P18
15
P71
20
YL
P75
20
DB/WT
6
C1 C2
4
AUTOMATIC
DAY/NIGHT
MIRROR
4 5
20 18
P34
B23
C20
B75 20 19
4 5 C19
EC1
A20 A18
P112
20
YL/WT
P112
20
YL/WT
P114
20
YL/BK
P114
20
YL/BK
P75
20
DB/WT
P71
20
YL
P64
20
YL/OR
P69
20
WT/RD
P65
20
DB/YL
POWER
MIRROR
B(-) B(-)
MIRROR
POWER
POWER
MIRROR
B(-) B(-)
MIRROR
POWER
(8W-44-6)
MEMORY/EXCEPT BUILT-UP-EXPORT
NS/GS
J988W-3 GS006206
M M
B15 B8 A27 A28 A26
YL/PK
20
P73
MIRROR
POWER
DRIVER
3 1 2 C1 C1 C1 C2 1 2 C2 3 C2
C1
2
C1 10
MODULE
MIRROR
SEAT/
MEMORY
1
C1
3
C1
P64
20
YL/OR
27
B23
P34
28
WT/RD
20
P69
26
DB/YL
20
P65
LEFT
MIRROR
POSITION
GROUND
POSITION
MIRROR
LEFT
POSITION
HORIZONTAL
MIRROR
LEFT
LEFT
MIRROR
COMMON
LEFT
MIRROR
VERTICAL HORIZONTAL
MIRROR
LEFT
C1
11 12
C1
8
B23
P18
15
P71
20
YL
P75
20
DB/WT
P75
20
DB/WT
P71
20
YL
P64
20
YL/OR
P69
20
WT/RD
P65
20
DB/YL
VERTICAL
MEMORY/BUILT-UP-EXPORT
8W - 62 - 7
GS006207 J988W-3
BATT A0
G300
8
Z1
14
BK
JUNCTION
BLOCK
2
18
FUSE
15A
POWER
DISTRIBUTION
CENTER
C2
30
C2
15 C2
F41
20
PK/VT
85 30
87 86
MIRROR
FOLD
RELAY RELAY
UNFOLD
MIRROR
87A 87 86 87A
30 85
C1
36
C2
2
YL/RD
20
P174
C1 74
MODULE
CONTROL
BODY
P171
20
VT/WT
FOLD
MIRROR
POWER
71 C1
6 C2
5
C2
DRIVER
POWER
MIRROR MIRROR
POWER
PASSENGER
C2
5
C2 6
P159
20
DG
P159
20
DG
P160
20
LB
P160
20
LB
11
C3 C4
11
POWER
FOLDING
MIRROR
SWITCH
2
1
P136
20
YL
SWITCH
MIRROR
FOLDING
39 C2
SIGNAL
36
C4
BK
20
Z1
POWER POWER
1 2
M M
1 UNFOLD
2 FOLD
RELAY RELAY
POWER
MIRROR
UNFOLD
POWER
(8W-10-8)
(8W-15-6)
(8W-12-2)
(8W-10-20)
(8W-10-9)
(8W-45-10)
(8W-12-19)
BUILT-UP-EXPORT
NS/GS
J988W-3 GS006208
8W-63 POWER SEAT
Component Page
Dri ver Heated Seat Back. . . . . . . . . . . . . . . .8W-63-7
Dri ver Heated Seat Cushi on . . . . . . . . . . . . .8W-63-7
Dri ver Heated Seat Modul e. . . . . . . . . . . . . .8W-63-7
Dri ver Heated Seat Swi tch . . . . . . . . . . . . . .8W-63-7
Dri ver Power Seat Swi tch . . . . . . . . . . . . . . .8W-63-2
Dri ver Seat Front Verti cal Motor . . . . . . . . .8W-63-2
Dri ver Seat Hori zontal Motor . . . . . . . . . . . .8W-63-2
Dri ver Seat Rear Verti cal Motor . . . . . . . . . .8W-63-2
Dri ver Seat Recl i ner Motor . . . . . . . . . . . . . .8W-63-2
DS01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-63-4
Fuse 12 (JB) . . . . . . . . . . . . . . . . . . . . . . .8W-63-7, 8
Fuse 28 (PDC). . . . . . . . . . . . . . . . . . . . . . . .8W-63-4
Fusi bl e Li nk . . . . . . . . . . . . . . . . . . . . . . .8W-63-2, 3
G300 . . . . . . . . . . . . . . . . . . . . .8W-63-2, 3, 4, 5, 7, 8
HS1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-63-7
HS2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-63-7
HS3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-63-8
HS4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-63-8
HS5D B09 . . . . . . . . . . . . . . . . . . . . . . . . .8W-63-2, 7
HS5P B56 . . . . . . . . . . . . . . . . . . . . . . . . .8W-63-3, 8
Juncti on Bl ock . . . . . . . . . . . . . . . . . . . .8W-63-4, 7, 8
Memory Power Seat Swi tch . . . . . . . . . .8W-63-4, 5, 7
Memory Seat Front Verti cal Motor . . . . . . . .8W-63-5
Memory Seat Front Verti cal
Posi ti on Sensor . . . . . . . . . . . . . . . . . . . . .8W-63-6
Component Page
Memory Seat Hori zontal Motor . . . . . . . . . . .8W-63-5
Memory Seat Hori zontal Posi ti on Sensor . . .8W-63-6
Memory Seat Rear Verti cal Motor . . . . . . . . .8W-63-5
Memory Seat Rear Verti cal
Posi ti on Sensor . . . . . . . . . . . . . . . . . . . . .8W-63-6
Memory Seat Recl i ne Posi ti on Sensor . . . . . .8W-63-6
Memory Seat Recl i ner Motor . . . . . . . . . . . . .8W-63-5
Memory Seat/Mi rror Modul e . . .8W-63-2, 3, 4, 5, 6, 7
Memory Set Swi tch . . . . . . . . . . . . . . . . . . . .8W-63-4
Passenger Heated Seat Back . . . . . . . . . . . . .8W-63-8
Passenger Heated Seat Cushi on . . . . . . . . . .8W-63-8
Passenger Heated Seat Modul e . . . . . . . . . . .8W-63-8
Passenger Heated Seat Swi tch . . . . . . . . . . .8W-63-8
Passenger Power Seat Swi tch . . . . . . . . . . . .8W-63-3
Passenger Seat Front Verti cal Motor . . . . . . .8W-63-3
Passenger Seat Hori zontal Motor . . . . . . . . .8W-63-3
Passenger Seat Rear Verti cal Motor . . . . . . .8W-63-3
Passenger Seat Recl i ner Motor . . . . . . . . . . .8W-63-3
Power Seat Ci rcui t Breaker . . . . . . . . . .8W-63-2, 3, 4
SS01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-63-6
SS02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-63-6
NS/GS 8W - 63 POWER SEAT 8W - 63 - 1
Z1
14
BK
BATT A2
POWER
SEAT
SWITCH
3
5
6 1
P17
14
RD/LB
P15
14
YL/LB RD/WT
14
P13
YL/WT
14
P11
9 8 2 4
P41
14
GY/WT
P43
14
GY/LB RD/LG
14
P21
YL/LG
14
P19
10 7
DRIVER
B A
M
M
B A A B
M
A B
MOTOR
HORIZONTAL FRONT
VERTICAL
MOTOR
MOTOR
RECLINER REAR
VERTICAL
MOTOR
2
1
S02
B09
BK
12
Z1
G300
2
4 3 1 2 2 1 4 3
M
DRIVER
SEAT SEAT
DRIVER
SEAT
DRIVER
SEAT
DRIVER
4 REARWARD
2 DOWN
1 UP
3 FORWARD
HEATED
SEAT OTHER
C2 8
MODULE
MIRROR
SEAT/
MEMORY
2
HS5D
B09
HS6D
S02
3
LINK
FUSIBLE
10A
A
(8W-63-7)
DRIVER
HEATED
SEAT
MODULE
TO
F35
14
RD
F35
14
RD
F35
14
RD
F35
14
RD
F35
14
RD
3
B09
S02
POWER
SEAT
CIRCUIT
BREAKER
30A
FUSED
B(+)
(8W-10-13)
(8W-15-5)
(8W-15-9)
(8W-62-3)
8W - 63 - 2 8W-63 POWER SEATS NS/GS
J988W-3 GS006302
RD
14
F35
B (+)
FUSED
8 C2
Z1
14
BK
BATT A2
POWER
SEAT
SWITCH
3
5
6 1
P16
14
RD/LB
P14
14
YL/LB RD/WT
14
P12
YL/WT
14
P10
8 9 2 4
P42
14
GY/WT
P44
14
GY/LB RD/LG
14
P20
YL/LG
14
P18
7 10
PASSENGER
A B
M
M
A B B A
M
B A
MOTOR
HORIZONTAL FRONT
VERTICAL
MOTOR
MOTOR
RECLINER REAR
VERTICAL
MOTOR
2
1
S02
B56
BK
12
Z1
G300
7
4 3 1 2 1 2 3 4
M
SEAT
PASSENGER
SEAT
PASSENGER
SEAT
PASSENGER
SEAT
PASSENGER
4 REARWARD
2 DOWN
1 UP
3 FORWARD
2
HS5P
B56
3
S02
HS6P
HEATED
SEATS OTHER
F35
14
RD
LINK
FUSIBLE
10A
B
(8W-63-8)
PASSENGER
HEATED
SEAT
MODULE
TO
F35
14
RD
F35
14
RD
S02
B56
3
POWER
SEAT
CIRCUIT
BREAKER
30A
MODULE
MIRROR
SEAT/
MEMORY
(8W-10-13)
(8W-15-5)
(8W-62-3)
NS/GS 8W-63 POWER SEATS 8W - 63 - 3
GS006303 J988W-3
RKE
INTER-
FACE FACE
INTER-
RKE
LG/RD
20
G96
LG/RD
20
G96
P34
B23
23
LG/RD
20
G96
MODULE
CONTROL
BODY REMOTE
KEYLESS
ENTRY
MODULE
C2 1 6
C1
19
RKE
INTERFACE
10
D01D
B02
BK
12
Z1
DS01
BK
20
Z1
MEMORY
POWER
SEAT
SWITCH
BK
20
Z1
1
BK
12
Z1
1
S02
B09
BK
14
Z1
2
G300
5
7
C2
GROUND
PK/WT
20
P24
D02
B01
7
PK/WT
20
P24 P23
20
PK/RD
6
P23
20
PK/RD PK/BK
20
P22
4
PK/BK
20
P22
MEMORY
NO. 2
MEMORY
NO. 1 SET
MEMORY
C1
21
C1
20 8
C1
SWITCH
SET
MEMORY
3 2 1
3
4 6 5
RD
14
F35
8 C2
FUSED
B(+)
BATT A2
2
PK
20
M1
B(+)
FUSED
C1 16
MEMORY
SEAT/
MIRROR
MODULE
PK
20
M1
BLOCK
JUNCTION
C1 13
BATT A0
5
28
FUSE
10A
POWER
DISTRIBUTION
CENTER
C3
A23
1 SET
2 MEM 1
3 MEM 2
POWER
SEAT
CIRCUIT
BREAKER
30A
FUSED
B(+)
GROUND
(8W-45-6)
(8W-61-5)
(8W-15-7)
(8W-63-5)
(8W-15-5)
(8W-10-13)
(8W-12-2)
(8W-10-8)
(8W-10-11)
(8W-10-9)
(8W-63-2)
(8W-63-3)
8W - 63 - 4 8W-63 POWER SEATS
MEMORY
NS/GS
J988W-3 GS006304
BK
12
Z1
BK
20
Z1
B09
S02
1
BK
14
Z1
GND
C2
7
P117
14
RD/LB
P115
14
YL/LB YL/WT
14
P111
RD/WT
14
P113 P121
14
RD/LG
P119
14
YL/LG GY/LB
14
P43
GY/WT
14
P41
B A
M
9
C2
RECLINE
RWD FWD
RECLINE
C2
4
DOWN
VERTICAL
FRONT
C2
10
UP
VERTICAL
FRONT
C2
5
DOWN
VERTICAL
REAR
C2
6
UP
VERTICAL
REAR
C2
3 1
C2
HORIZ.
RWD FWD
HORIZ.
C2
2
G300
2
MOTOR
RECLINER
B A
M
M
B A
M
A B
MOTOR
HORIZONTAL
FRONT
VERTICAL
MOTOR
REAR
VERTICAL
MOTOR
RD
20
P9 P17
22
RD/LB
P15
22
YL/LB RD/WT
22
P13
YL/WT
22
P11 P48
22
GY/WT
P40
22
GY/LB RD/LG
22
P21
YL/LG
22
P19
SEAT
RECLINE
RWD
4 C3
SEAT
RECLINE
FWD
15 C3
SEAT
FRONT
DOWN
1 C3
SEAT
FRONT
UP
12 C3 C3 13
UP
REAR
SEAT
C3 2
DOWN
REAR
SEAT SEAT
FWD
14 C3
SEAT
RWD
3 C3 C3 11
B(+)
FUSED
5
POWER
SEAT
SWITCH
3 6 1 9 8 2 4 10 7
MEMORY
MODULE
MIRROR
SEAT/
MEMORY
4 3 1 2 1 2 3 4
SEAT
MEMORY
SEAT
MEMORY
SEAT
MEMORY
MEMORY
SEAT
4 REARWARD
2 DOWN
1 UP
3 FORWARD
(8W-15-5)
NS/GS 8W-63 POWER SEATS
MEMORY
8W - 63 - 5
GS006305 J988W-3
BR
22
P26
LB/RD
22
P27
VT/RD
22
P25
LB
22
P47
BR/RD
20
P28
BR/RD
20
P28
BR/RD
20
P28
BR/RD
20
P28
BR/RD
20
P28
BR/WT
20
P29
BR/WT
20
P29
BR/WT
20
P29
BR/WT
20
P29
BR/WT
20
P29
SS01
SS02
SENSOR
POSITION
RECLINE
SEAT
MEMORY
MEMORY
SEAT
HORIZONTAL
POSITION
SENSOR
SENSOR
MEMORY
SEAT
FRONT
VERTICAL
POSITION
POSITION
VERTICAL
REAR
SEAT
MEMORY
SENSOR
A B
C
C
B A
A B
C
C3 17 C3 18 C3 10 C3 7 C3 8 20 C3
A
B C
SENSE
POSITION
RECLINER HORIZONTAL
POSITION
SENSE
FRONT
SENSE
POSITION
SEAT
VERTICAL
6V
SUPPLY
MEMORY
SEAT/
MIRROR
MODULE
VERTICAL
SEAT
POSITION
SENSE
REAR
SEAT
COMMON
SENSE
POSITION
SEAT SEAT
MEMORY
NS/GS
J988W-3 GS006306
SWITCH
SEAT
HEATED
DRIVER
DRIVER
HEATED
SEAT
CUSHION
DRIVER
HEATED
SEAT
BACK
DRIVER
HEATED
SEAT
MODULE
A
(8W-63-2)
FUSIBLE
LINK
FROM
D A E F C B
A B
D
D B
A F E
A C B
2
G300
FUSED
B(+)
GROUND FEED
BACK
HEATED
SEAT
DRIVER
GROUND
DRIVER
SEAT
HEATED
GROUND
HS1
F35
18
RD
P86
20
VT
P7
20
WT/BK
Z1
18
BK
Z1
18
BK
Z1
14
BK
P87
18
RD/WT
P89
20
BK/RD
P88
18
RD/WT
Z1
18
BK
B09
HS5D
1
Z1
12
BK
Z1
18
BK
HEATED
SEAT
BACK DRIVER
SEAT
HEATED
GROUND
FUSED
IGNITION
(RUN) (RUN)
IGNITION
FUSED
HS2
4
B09
HS5D
F20
20
WT
10A
FUSE
12
RUN A22
JUNCTION
BLOCK
14
C2
1
S02
HS6D
Z1
14
BK
MODULE
MIRROR
SEAT/
MEMORY
Z1
14
BK
7
BK
20
Z1
1
MEMORY
POWER
SEAT
SWITCH
HEATED
SEAT
DRIVER
C2
HEATED
SEAT
TEMPERATURE
SENSOR SWITCH
SEAT
HEATED
DRIVER
DRIVER
HEATED
SEAT
SWITCH SENSOR
TEMPERATURE
SEAT
HEATED
GROUND GROUND
(8W-15-5)
(8W-12-12)
(8W-12-2)
(8W-10-14)
(8W-63-5) (8W-63-5)
NS/GS 8W-63 POWER SEATS
HEATED
8W - 63 - 7
GS006307 J988W-3
SWITCH
SEAT
HEATED
PASSENGER
PASSENGER
HEATED
SEAT
CUSHION
PASSENGER
HEATED
SEAT
BACK
PASSENGER
HEATED
SEAT
MODULE
B
(8W-63-3)
FUSIBLE
LINK
FROM
D A E F C B
A B
D
D B
A F E
A C B
7
G300
FUSED
B(+)
GROUND
HEATED
SEAT
DRIVER
GROUND
DRIVER
SEAT
HEATED
GROUND
HS3
F35
18
RD
P86
20
VT
P8
20
WT/BK
Z1
18
BK
Z1
18
BK
Z1
14
BK
P87
18
RD/WT
P89
20
BK/RD
P88
18
RD/WT
Z1
18
BK
B56
HS5P
1
Z1
12
BK
Z1
18
BK
HEATED
SEAT
BACK DRIVER
SEAT
HEATED
GROUND
FUSED
IGNITION
(RUN) (RUN)
IGNITION
FUSED
HS4
4
B56
HS5P
F20
20
WT
10A
FUSE
12
RUN A22
JUNCTION
BLOCK
7
C2
HEATED
SEAT
DRIVER
HEATED
SEAT
TEMPERATURE
SENSOR SWITCH
SEAT
HEATED
PASSENGER
PASSENGER
HEATED
SEAT
SWITCH SENSOR
TEMPERATURE
SEAT
HEATED
BACK
SEAT
HEATED
(8W-15-9)
(8W-12-12)
(8W-12-2)
(8W-10-14)
HEATED
NS/GS
J988W-3 GS006308
8W-70 SPLICE INFORMATION
Component Page
AWS1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-13
AWS2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-31-3
BS01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-70-2
BS02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-70-2
BS03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-47-4
BS05 . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-4, 31
BS06 . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-4, 31
BS08 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-5
BS10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-45-8
BS15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-50-6
BS16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-50-8
BS17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-70-3
BS19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-41-2
BS30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-36
BS31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-3
BS32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-33
BS33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-25
BS40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-3
BS41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-3
CS01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-21
CS02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-20
CS03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-70-3
CS04 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-9
CS06 . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-11, 12
CS1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-21
DS01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-5
ES01 (DI ESEL) . . . . . . . . . . . . . . . . . . . . . . .8W-15-3
ES01 (GAS) . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-28
ES02 (DI ESEL) . . . . . . . . . . . . . . . . . . . . . . .8W-15-3
ES02 (GAS) . . . . . . . . . . . . . . . . . . . . . .8W-70-4, 5, 6
ES03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-70-7
ES05 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-70-8
ES06 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-25
ES07 (DI ESEL) . . . . . . . . . . . . . . . . . . . . . .8W-42-10
ES07 (GAS) . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-13
ES08 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-25
ES08 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-70-8
ES09 (DI ESEL) . . . . . . . . . . . . . . . . . . . . . .8W-42-10
ES09 (GAS) . . . . . . . . . . . . . . . . . . . . . . . . . .8W-20-2
Component Page
ES10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-70-8
ES11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-2
ES12 (DI ESEL) . . . . . . . . . . . . . . . . . . . . . . .8W-15-3
ES12 (GAS) . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-23
ES13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-4
ES13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-40-5
ES14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-4
ES17 (2.0L/2.4L) . . . . . . . . . . . . . . . . . . . . . .8W-70-9
ES17 (3.3L/3.8L) . . . . . . . . . . . . . . . . . . . . .8W-30-22
ES18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-2
ES21 . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-70-4, 5, 6
ES23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-2
ES24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-3
ES26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-20-3
ES28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-20-3
ES29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-25
ES30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-3
ES31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-3
ES37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-32
ES40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-27
ES99 (2.0L) . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-24
FS01 (2.4L) . . . . . . . . . . . . . . . . . . . . . . . . . .8W-70-5
FS01 (3.3L/3.8L) . . . . . . . . . . . . . . . . . . . . .8W-10-24
FS02 (2.4L) . . . . . . . . . . . . . . . . . . . . . . . . . .8W-70-7
FS02 (3.3L/3.8L) . . . . . . . . . . . . . . . . . . . . . .8W-70-6
FS03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-23
HS1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-63-7
HS2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-63-7
HS3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-63-8
HS4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-63-8
JS01B . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-70-10
JS02B . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-70-10
JS03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-70-9
PS01 . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-4, 31
PS02 . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-4, 31
RFS1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-42-8
RFS2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-2
RFS2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-42-8
SS01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-63-6
SS02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-63-6
NS/GS 8W - 70 SPLICE INFORMATION 8W - 70 - 1
CONTROLLER
ANTI-LOCK
BRAKE SWITCH
LAMP
STOP
5
ASSEMBLY
LAMP
REAR
LEFT RIGHT
REAR
LAMP
ASSEMBLY
5 3
LAMP
STOP
MOUNTED
HIGH
CENTER
L50
20
WT/TN
L50
20
WT/TN
L50
18
WT/TN
J02A
L15
2
2
LJ01
B17
WT/TN
18
L50
L50
18
WT/TN
BS01
TRAILER
TOW OTHERS
5
T08
B98
L50
18
WT/TN
12 5
L50
18
WT/TN
L50
18
WT/TN
B99
T05
5
TOW OTHERS
TRAILER
L50
18
WT/TN
1
RELAY
TURN
STOP/
LEFT
LEFT
3 1
RELAY
COMBINATION
RIGHT
STOP/
TURN
RELAY
3
L50
18
WT/TN
L50
18
WT/TN
3
(3.8L)
SOLENOID
DRIVE
WHEEL
ALL
6
2
TRANSMISSION
RANGE
SENSOR
3
LEFT
REAR
LAMP
ASSEMBLY ASSEMBLY
LAMP
REAR
RIGHT
3
L1
18
VT/BK
B33
E36
10
VT/BK
18
L1
L1
20
VT/BK
L1
20
VT/BK
BS02
B13
AW4
2
L1
20
VT/BK
L1
20
VT/BK
3
EC1
C19
B75
C20
13
EATX MTX
SIGNAL
SIGNAL
COMBINATION
RELAY
RIGHT
L50 18 WT/TN
L1
18
VT/BK
2
C2
2
C1
AWS2
AUTOMATIC
DAY/NIGHT
MIRROR
*6 *6
WT/TN
18
L50
44
(DIESEL)
MODULE
CONTROL
POWERTRAIN
SWITCH
BACK-UP
GAS DIESEL
E36
B33 B33
E120
*4 *4
* BUILT-UP-EXPORT
10 10
(8W-35-3) (8W-33-5)
(8W-51-4)
(8W-51-5)
(8W-51-4)
(8W-51-5)
(8W-51-7)
(8W-54-3)
(8W-54-3)
(8W-54-3)
(8W-31-3)
(8W-31-3)
(8W-51-4)
(8W-51-5)
(8W-51-4)
(8W-51-5)
(8W-54-3)
(8W-44-6)
(8W-30-39)
(8W-51-5)
8W - 70 - 2 8W-70 SPLICE INFORMATION NS/GS
J988W-3 GS007002
C70
12
DG
C70
12
DG DG
12
C70
B23
P34 35
A35
C70
12
DG
BS17
UNIT
A/C
REAR
6 3
SWITCH
CONTROL
REAR
BLOWER
REAR REAR
BLOWER
FRONT
CONTROL
SWITCH
1
BR
20
M20
BR
20
M20
BR
20
M20
BR
20
M20
LEFT
2
LAMP
READING
MID
LEFT
REAR
READING
LAMP
2
2
LAMP
READING
REAR
RIGHT RIGHT
MID
READING
LAMP
2
CS03
M20
20
BR BR
20
M20
A
MIRROR
VANITY
VISOR/
RIGHT
LAMPS LAMPS
LEFT
VISOR/
VANITY
MIRROR
A
M20
20
BR BR
20
M20
1
B75
C20
B5
5 P18
B23
BR
20
M20
OTHERS
CONSOLE
OVERHEAD
2
SWITCH
LAMPS/
READING
FRONT FRONT
READING
LAMPS/
SWITCH
6
C1
BODY
CONTROL
MODULE
80
LAMP
BOX
GLOVE
2
HEATER
M20
20
BR
M20
20
BR
3
CENTER
DOME
LAMP LAMP
DOME
REAR
3
M20
20
BR
M20
20
BR
(8W-42-6)
(8W-42-6) (8W-42-6)
(8W-44-4) (8W-44-4)
(8W-44-4) (8W-44-4)
(8W-44-3) (8W-44-3)
(8W-44-2) (8W-44-2)
(8W-45-8) (8W-44-2)
(8W-44-4) (8W-44-4)
NS/GS 8W-70 SPLICE INFORMATION 8W - 70 - 3
GS007003 J988W-3
A/C
PRESSURE
TRANSDUCER
1
BK/LB
18
K4 K4
18
BK/LB
2
SENSOR
POSITION
CRANKSHAFT
SENSOR
SPEED
VEHICLE
2
POWERTRAIN
CONTROL
MODULE
A 1
CAMSHAFT
POSITION
SENSOR
SENSOR
POSITION
THROTTLE
ENGINE
COOLANT
TEMPERATURE
SENSOR
K4
18
BK/LB
K4
18
BK/LB
K4
18
BK/LB
ES02
(2.0L)
BK/LB
18
K4
BK/LB
18
K4
(2.0L)
ES21
SENSOR
OXYGEN
HEATED
DOWNSTREAM
UPSTREAM
HEATED
OXYGEN
SENSOR
K4
20
BK/LB
1
E36
B33
K4
18
BK/LB
2
SENSOR
KNOCK
1
K4
18
BK/LB BK/LB
18
K4
43
C2
2
K4
18
BK/LB
SENSOR
PRESSURE
ABSOLUTE
MANIFOLD
TEMPERATURE/
AIR
INTAKE
BK/LB
18
K4
3
3
(8W-30-10) (8W-30-8)
(8W-30-11)
(8W-30-8)
(8W-30-8)
(8W-30-11)
(8W-30-10)
(8W-30-7)
(8W-30-7)
(8W-30-10)
(8W-30-10)
8W - 70 - 4 8W-70 SPLICE INFORMATION
2.0L
NS/GS
J988W-3 GS007004
C2
B33
E36
1
BK/LB
20
K4
3
SENSOR
OXYGEN
HEATED
UPSTREAM
DOWNSTREAM
HEATED
OXYGEN
SENSOR
3
43
ES21
K4
18
BK/LB
K4
18
BK/LB
K4
18
BK/LB
K4
18
BK/LB
BK/LB
18
K4
BK/LB
18
K4
BK/LB
18
K4
BK/LB
18
K4
BK/LB
18
K4
F09
E69
5
FS01
TRANSDUCER
PRESSURE
A/C
1
AIR
ES02
BK/LB
18
K4
BK/LB
18
K4
BK/LB
18
K4
BK/LB
18
K4
BK/LB
18
K4
BK/LB
18
K4
BK/LB
18
K4
KNOCK
SENSOR
2
1
SENSOR
TEMPERATURE
COOLANT
ENGINE
MANIFOLD
ABSOLUTE
PRESSURE
SENSOR
SENSOR
POSITION
CAMSHAFT
2
1
THROTTLE
POSITION
SENSOR SENSOR
POSITION
CRANKSHAFT
2
(EATX)
51
TRANSMISSION
CONTROL
MODULE
MODULE
CONTROL
POWERTRAIN
2
VEHICLE
SPEED
SENSOR
SENSOR
TEMPERATURE
INTAKE
A
1
(8W-30-7)
(8W-30-7)
(8W-30-16)
(8W-30-16)
(8W-30-16)
(8W-30-16)
(8W-30-14)
(8W-30-17) (8W-30-14)
(8W-31-4)
(8W-30-7)
(8W-30-17)
(8W-30-17)
NS/GS 8W-70 SPLICE INFORMATION
2.4L
8W - 70 - 5
GS007005 J988W-3
2
K4
18
BK/LB
SENSOR
BK/LB
18
K4
UPSTREAM
HEATED
OXYGEN
3
C2
BK/LB
20
K4
1
B33
E36
3 2
A
POWERTRAIN
CONTROL
MODULE
MODULE
CONTROL
TRANSMISSION
43
CRANKSHAFT
POSITION
SENSOR
SENSOR
POSITION
THROTTLE
1
SENSOR
PRESSURE
ABSOLUTE
MANIFOLD
ENGINE
COOLANT
TEMPERATURE
SENSOR
1
K4
18
BK/LB
K4
18
BK/LB
K4
18
BK/LB
K4
18
BK/LB
ES02
A/C
PRESSURE
TRANSDUCER
FS02
14
E78
F02
K4
18
BK/LB
K4
18
BK/LB
K4
18
BK/LB
K4
18
BK/LB BK/LB
18
K4
BK/LB
18
K4
BK/LB
18
K4
ES21
1
SENSOR
OXYGEN
HEATED
DOWNSTREAM
51
KNOCK
SENSOR
(3.8L)
FLEXIBLE
FUEL
SENSOR
(3.3L/ETHANOL)
2
K4
18
BK/LB
2
SENSOR
POSITION
CAMSHAFT
K4
18
BK/LB
(8W-30-21)
(8W-30-21)
(8W-31-4)
(8W-30-22)
(8W-30-25)
(8W-30-24)
(8W-30-24)
(8W-30-24)
(8W-30-21)
(8W-30-24)
(8W-30-22)
(8W-30-22)
3.3L/3.8L
NS/GS
J988W-3 GS007006
2
A/C
PRESSURE
TRANSDUCER SENSOR
POSITION
THROTTLE
B
SENSOR
PRESSURE
ABSOLUTE
MANIFOLD
2
F02
E78
K6
18
VT/WT
K6
18
VT/WT
K6
18
VT/WT
ES03
(3.3L/3.8L)
C2
61
POWERTRAIN
CONTROL
MODULE
VT/WT
18
K6
MODULE
CONTROL
POWERTRAIN
MANIFOLD
ABSOLUTE
PRESSURE
SENSOR
THROTTLE
POSITION
SENSOR
TRANSDUCER
PRESSURE
A/C
K6
18
VT/WT
61
C2
VT/WT
18
K6
3
(2.0L/2.4L)
ES03
(2.4L)
FS02
K6
18
VT/WT
B
2
E69
F09
8
K6
18
VT/WT
K6
18
VT/WT
K6
18
VT/WT
3
VT/WT
18
K6
C
(2.0L)
SENSOR
PRESSURE
ABSOLUTE
MANIFOLD
TEMPERATURE/
AIR
INTAKE
K6
18
VT/WT
K6
18
VT/WT
2.0L 2.4L
(8W-30-24) (8W-30-25)
(8W-30-24)
(8W-30-24)
(8W-30-11)
(8W-30-17)
(8W-30-11)
(8W-30-17)
(8W-30-10)
(8W-30-16)
(8W-30-16)
(8W-30-10)
GS007007 J988W-3
1
SENSOR
SPEED
OUTPUT
DB/BK
18
T13
3
SENSOR
RANGE
TRANSMISSION
T13
18
DB/BK
T13
18
DB/BK DB/BK
18
T13
ES10
TURBINE
SPEED
SENSOR
1 13
TRANSMISSION
CONTROL
MODULE
C1
35
POWERTRAIN
CONTROL
MODULE MODULE
CONTROL
TRANSMISSION
12 2
SENSOR
POSITION
THROTTLE
ES08
K22
18
OR/DB OR/DB
18
K22 K22
18
OR/DB
GY/BK
18
K24 K24
18
GY/BK GY/BK
18
K24
ES05
CRANKSHAFT
POSITION
SENSOR
3 6
TRANSMISSION
CONTROL
MODULE MODULE
CONTROL
POWERTRAIN
32
C1
SHAFT
(8W-31-3)
(8W-31-5) (8W-31-3) (8W-31-5)
(8W-30-17)
(8W-30-25)
(8W-31-4) (8W-30-17)
(8W-30-25)
(8W-30-14)
(8W-30-22)
(8W-31-4) (8W-30-14)
(8W-30-22)
EATX
NS/GS
J988W-3 GS007008
DB/WT
22
C34
5
P30
J01D
HVAC
CONTROL
C1
CONTROL
A/C
12
1
ACTUATOR
DOOR
MODE
JS03
C34
20
DB/WT DB/WT
20
C34
DB/WT
20
C34
BLEND
DOOR
ACTUATOR
5
C34
20
DB/WT
RECIRCULATION
DOOR
ACTUATOR
1
K7
18
OR
1
OR
18
K7
OR
18
K7
C2
MODULE
CONTROL
POWERTRAIN
44
SENSOR
POSITION
CAMSHAFT
ES17
K7
18
OR
CRANKSHAFT
POSITION
SENSOR
1
VEHICLE
SPEED
SENSOR
1
HEATER
1
(3.3L/ETHANOL)
SENSOR
FUEL
FLEXIBLE
K7
18
OR
(8W-42-5)
(8W-42-5)
(8W-42-5) (8W-42-5) (8W-42-5)
(8W-30-8)
(8W-30-14)
(8W-30-8)
(8W-30-14)
(8W-30-8)
(8W-30-14)
(8W-30-11)
(8W-30-22)
GS007009 J988W-3
(2.0L/2.4L)
SENSOR
TEMPERATURE
EVAPORATOR
2 4
ACTUATOR
DOOR
MODE BLEND
DOOR
ACTUATOR
4 2
ACTUATOR
DOOR
ZONE
DB/GY
20
C57 C57
20
DB/GY DB/GY
20
C57
DB/GY
20
C57
JS01B
ACTUATOR
DOOR
BLEND MODE
DOOR
ACTUATOR
2 2 4
C57
20
DB/GY
2
P30
J01D
DB/GY
22
C57
C1
9
C1 20
C26
22
PK/DB
P30
J01D
1
PK/DB
20
C26
C26
20
PK/DB PK/DB
20
C26
PK/DB
20
C26
JS02B
CONTROL
HEATER
A/C
A/C
ACTUATOR
DOOR
ZONE
A/C
(DUAL ZONE A/C)
(DUAL ZONE A/C)
(8W-42-5) (8W-42-5) (8W-42-5)
(8W-42-5)
(8W-42-5)
(8W-42-5) (8W-42-5)
(8W-42-5)
8W - 70 - 10 8W-70 SPLICE INFORMATION NS/GS
J988W-3 GS007010
BK/LB
20
K4
BK/LB
20
K4
BK/LB
20
K4
BK/LB
18
K4
BK/LB
20
K4
33
MODULE
CONTROL
POWERTRAIN
SENSOR
POSITION
PEDAL
ACCELERATOR
3
A/C
PRESSURE
TRANSDUCER
1
(DIESEL)
BS34
6
E97
B106
2
SENSOR
SPEED
VEHICLE ENGINE
COOLANT
TEMPERATURE
SENSOR
2
K4
20
BK/LB
TURBO
BOOST
PRESSURE
SENSOR
BK/LB
18
K4
1
FUEL
PUMP
MODULE
4
BK/LB
20
K4 K4
20
BK/LB
(DIESEL)
ES05
(8W-30-38)
(8W-30-38)
(8W-30-38)
(8W-30-36)
(8W-30-36) (8W-30-34)
(8W-30-33)
NS/GS 8W-70 SPLICE INFORMATION
DIESEL
8W - 70 - 11
GS007011 J988W-3
8W-80 CONNECTOR PIN-OUTS
Component Page
A/C Heater Control - C1 . . . . . . . . . . . . . . . .8W-80-5
A/C Heater Control - C2 . . . . . . . . . . . . . . . .8W-80-5
A/C Compressor Cl utch . . . . . . . . . . . . . . . . .8W-80-5
A/C Pressure Transducer (Gas) . . . . . . . . . . .8W-80-6
A/C Pressure Transducer (Di esel ) . . . . . . . . .8W-80-6
A/C Zone Door Actuator . . . . . . . . . . . . . . . . .8W-80-6
Accel erator Pedal Posi ti on Sensor (Di esel ) . .8W-80-6
Ai rbag Control Modul e - C1 . . . . . . . . . . . . .8W-80-6
Ai rbag Control Modul e - C2 . . . . . . . . . . . . .8W-80-7
Al l Wheel Dri ve Sol enoi d - C1 . . . . . . . . . . . .8W-80-7
Al l Wheel Dri ve Sol enoi d - C2 . . . . . . . . . . . .8W-80-7
Ambi ent Ai r Temperature Sensor . . . . . . . . .8W-80-7
Ash Recei ver Lamp (LHD). . . . . . . . . . . . . . .8W-80-8
Ash Recei ver Lamp (RHD) . . . . . . . . . . . . . .8W-80-8
B09 HS5D . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-9
B09 S02. . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-9
B13 AW4 . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-9
B17 LJ01. . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-9
B23 P18. . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-10
B23 P34 . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-11
B33 E120. . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-12
B33 E36. . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-12
B56 HS5P . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-12
B56 S02 . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-12
B70 E43. . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-13
B75 C20. . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-13
B98 T08. . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-14
B99 T05. . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-14
Back-Up Swi tch . . . . . . . . . . . . . . . . . . . . . .8W-80-14
Bl end Door Actuator . . . . . . . . . . . . . . . . . .8W-80-14
Body Control Modul e - C1 . . . . . . . . . . . . . .8W-80-15
Body Control Modul e - C2 . . . . . . . . . . . . . .8W-80-16
Brake Pressure Swi tch . . . . . . . . . . . . . . . .8W-80-16
C19 EC1 . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-17
Camshaft Posi ti on Sensor . . . . . . . . . . . . . .8W-80-17
Center Dome Lamp . . . . . . . . . . . . . . . . . . .8W-80-17
Center Hi gh Mounted Stop Lamp . . . . . . . .8W-80-17
Cl ockspri ng - C1 . . . . . . . . . . . . . . . . . . . . .8W-80-18
Cl ockspri ng - C2 . . . . . . . . . . . . . . . . . . . . .8W-80-18
Cl utch I nterl ock Swi tch . . . . . . . . . . . . . . . .8W-80-18
Cl utch I nterl ock Swi tch Jumper . . . . . . . . .8W-80-18
Cl utch Swi tch . . . . . . . . . . . . . . . . . . . . . . .8W-80-18
Control l er Anti -Lock Brake . . . . . . . . . . . . .8W-80-19
Crank Case Heater . . . . . . . . . . . . . . . . . . .8W-80-19
Crankshaft Posi ti on Sensor . . . . . . . . . . . . .8W-80-19
D01D B02 . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-20
D01P B03 . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-20
D02 B01 . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-20
D02 B120 (LHD) . . . . . . . . . . . . . . . . . . . . .8W-80-21
D02 B120 (RHD) . . . . . . . . . . . . . . . . . . . . .8W-80-21
Data Li nk Connector . . . . . . . . . . . . . . . . . .8W-80-22
Component Page
Downstream Heated Oxygen Sensor . . . . . .8W-80-22
Dri ver Door Arm/Di sarm Swi tch . . . . . . . . .8W-80-22
Dri ver Door Courtesy Lamp . . . . . . . . . . . .8W-80-22
Dri ver Door Lock Motor . . . . . . . . . . . . . . . .8W-80-23
Dri ver Door Lock Swi tch . . . . . . . . . . . . . . .8W-80-23
Dri ver Heated Seat Back . . . . . . . . . . . . . . .8W-80-23
Dri ver Heated Seat Cushi on . . . . . . . . . . . .8W-80-23
Dri ver Heated Seat Modul e . . . . . . . . . . . . .8W-80-23
Dri ver Heated Seat Swi tch . . . . . . . . . . . . .8W-80-24
Dri ver Power Mi rror - C1 . . . . . . . . . . . . . .8W-80-24
Dri ver Power Mi rror - C2 . . . . . . . . . . . . . .8W-80-24
Dri ver Power Seat Swi tch . . . . . . . . . . . . . .8W-80-25
Dri ver Power Wi ndow Swi tch . . . . . . . . . . .8W-80-25
Dri ver Seat Front Verti cal Motor . . . . . . . . .8W-80-25
Dri ver Seat Hori zontal Motor . . . . . . . . . . .8W-80-25
Dri ver Seat Rear Verti cal Motor . . . . . . . . .8W-80-26
Dri ver Seat Recl i ner Motor . . . . . . . . . . . . .8W-80-26
Dri ver Wi ndow Motor . . . . . . . . . . . . . . . . .8W-80-26
E40 RF3 . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-26
E69 F09. . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-27
E78 F02. . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-27
E95 B107. . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-27
E96 B108. . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-28
E97 B106. . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-28
EGR Sol enoi d (2.4L MTX/3.3L/3.8L) . . . . . .8W-80-28
EGR Sol enoi d (Di esel ) . . . . . . . . . . . . . . . . .8W-80-28
El ectri c Wi per De-I cer - C1 . . . . . . . . . . . . .8W-80-29
El ectri c Wi per De-I cer - C2 . . . . . . . . . . . . .8W-80-29
Engi ne Cool ant Temperature Sensor
(Di esel ) . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-29
(Gas) . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-29
Engi ne Oi l Pressure Swi tch . . . . . . . . . . . . .8W-80-29
Engi ne Speed Sensor (Di esel ) . . . . . . . . . . .8W-80-30
Evap Leak Detecti on Pump
(Except Bui l t-Up-Export). . . . . . . . . . . . .8W-80-30
Evap/Purge Sol enoi d . . . . . . . . . . . . . . . . . .8W-80-30
Evaporator Temperature Sensor . . . . . . . . .8W-80-30
Fl exi bl e Fuel Sensor . . . . . . . . . . . . . . . . . .8W-80-30
Front Bl ower Motor . . . . . . . . . . . . . . . . . . .8W-80-31
Front Bl ower Motor Resi stor Bl ock . . . . . . .8W-80-31
Front Ci gar Li ghter/Power Outl et . . . . . . . .8W-80-31
Front Readi ng Lamps/Swi tch . . . . . . . . . . .8W-80-32
Front Readi ng Lamps/Swi tch
(Overhead Consol e) . . . . . . . . . . . . . . . . .8W-80-32
Front Washer Motor . . . . . . . . . . . . . . . . . .8W-80-32
Fuel Heater . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-32
Fuel I njector No. 1 (2.0L/2.4L). . . . . . . . . . .8W-80-33
NS/GS 8W - 80 CONNECTOR PIN-OUTS 8W - 80 - 1
Component Page
Fuel Pump Modul e . . . . . . . . . . . . . . . . . . .8W-80-35
Fuel Tank Modul e . . . . . . . . . . . . . . . . . . . .8W-80-35
G200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-35
G300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-36
G301 (Di esel ). . . . . . . . . . . . . . . . . . . . . . . .8W-80-37
G301 (Gas) . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-37
G302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-38
G400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-38
Generator . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-38
Gl ove Box Lamp . . . . . . . . . . . . . . . . . . . . .8W-80-39
Gl ow Pl ug Rel ay . . . . . . . . . . . . . . . . . . . . .8W-80-39
HS6D S02 . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-39
HS6P S02 . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-39
Headl amp Swi tch - C1. . . . . . . . . . . . . . . . .8W-80-39
Headl amp Swi tch - C2. . . . . . . . . . . . . . . . .8W-80-40
Headl amp Washer . . . . . . . . . . . . . . . . . . . .8W-80-40
Hi gh Note Horn . . . . . . . . . . . . . . . . . . . . . .8W-80-40
Hood Ajar Swi tch. . . . . . . . . . . . . . . . . . . . .8W-80-41
Horn/Speed Control Swi tch . . . . . . . . . . . . .8W-80-41
I dl e Ai r Control Motor . . . . . . . . . . . . . . . . .8W-80-41
I gni ti on Coi l Pack (2.0L/2.4L) . . . . . . . . . . .8W-80-41
I gni ti on Coi l Pack (3.3L/3.8L) . . . . . . . . . . .8W-80-41
I gni ti on Swi tch - C1 . . . . . . . . . . . . . . . . . .8W-80-42
I nstrument Cl uster . . . . . . . . . . . . . . . . . . .8W-80-42
I ntake Ai r Temperature Sensor . . . . . . . . . .8W-80-43
I ntake Ai r Temperature/Mani fol d
Absol ute Pressure Sensor . . . . . . . . . . . . 8W-80-43
J02A L15 . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-43
J03A L16 . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-43
Juncti on Bl ock - C1 . . . . . . . . . . . . . . . . . . .8W-80-44
Key-I n Hal o Lamp . . . . . . . . . . . . . . . . . . . .8W-80-48
Key-I n Swi tch . . . . . . . . . . . . . . . . . . . . . . .8W-80-48
Knock Sensor . . . . . . . . . . . . . . . . . . . . . . . .8W-80-48
Left Combi nati on Rel ay . . . . . . . . . . . . . . . .8W-80-48
Left Door Speaker . . . . . . . . . . . . . . . . . . . .8W-80-48
Left Fog Lamp (Bui l t-Up-Export) . . . . . . . .8W-80-49
Left Fog Lamp (Except Bui l t-Up-Export). . .8W-80-49
Left Front Panel Speaker . . . . . . . . . . . . . .8W-80-49
Left Front Park/Turn Si gnal Lamp
(Bui l t-Up-Export) . . . . . . . . . . . . . . . . . .8W-80-49
Left Front Park/Turn Si gnal Lamp
(Except Bui l t-Up-Export) . . . . . . . . . . . . 8W-80-49
Left Front Speaker . . . . . . . . . . . . . . . . . . .8W-80-49
Left Front Wheel Speed Sensor . . . . . . . . . .8W-80-50
Component Page
Left Headl amp (Bui l t-Up-Export) . . . . . . . .8W-80-50
Left Headl amp (Except Bui l t-Up-Export) . .8W-80-50
Left Headl amp Level i ng Motor
(Bui l t-Up-Export) . . . . . . . . . . . . . . . . . .8W-80-50
Left Hi gh Headl amp (Chrysl er)
Left Li ftgate Fl ood Lamp. . . . . . . . . . . . . . .8W-80-51
Left Low Headl amp (Chrysl er)
Left Mi d Readi ng Lamp. . . . . . . . . . . . . . . .8W-80-51
Left Rear Door Ajar Swi tch . . . . . . . . . . . . .8W-80-51
Left Rear Lamp Assembl y
(Bui l t-Up-Export) . . . . . . . . . . . . . . . . . .8W-80-51
Left Rear Lamp Assembl y
Left Rear Pi l l ar Speaker . . . . . . . . . . . . . . .8W-80-52
Left Rear Readi ng Lamp . . . . . . . . . . . . . . .8W-80-52
Left Rear Sl i di ng Door Contacts . . . . . . . . .8W-80-52
Left Rear Speaker . . . . . . . . . . . . . . . . . . . .8W-80-52
Left Rear Vent Motor (LHD) . . . . . . . . . . . .8W-80-52
Left Rear Vent Motor (RHD) . . . . . . . . . . . .8W-80-53
Left Rear Wheel Speed Sensor . . . . . . . . . .8W-80-53
Left Repeater Lamp. . . . . . . . . . . . . . . . . . .8W-80-53
Left Stop/Turn Si gnal Rel ay . . . . . . . . . . . .8W-80-53
Left Vi sor/Vani ty Mi rror Lamps . . . . . . . . .8W-80-53
Li cense Lamp . . . . . . . . . . . . . . . . . . . . . . .8W-80-54
Li ftgate Ajar Swi tch . . . . . . . . . . . . . . . . . .8W-80-54
Li ftgate Arm/Di sarm Swi tch . . . . . . . . . . . .8W-80-54
Li ftgate Lock Motor . . . . . . . . . . . . . . . . . . .8W-80-54
Low Cool ant Level Swi tch . . . . . . . . . . . . . .8W-80-54
Low Note Horn . . . . . . . . . . . . . . . . . . . . . .8W-80-54
Low Washer Fl ui d Swi tch . . . . . . . . . . . . . .8W-80-54
Mani fol d Absol ute Pressure Sensor . . . . . . .8W-80-55
Memory Power Seat Swi tch . . . . . . . . . . . . .8W-80-55
Memory Seat Front Verti cal Motor . . . . . . .8W-80-55
Memory Seat Front Verti cal
Posi ti on Sensor . . . . . . . . . . . . . . . . . . . .8W-80-55
Memory Seat Hori zontal Motor . . . . . . . . . .8W-80-55
Memory Seat Hori zontal Posi ti on Sensor . .8W-80-56
Memory Seat Rear Verti cal Motor . . . . . . . .8W-80-56
Memory Seat Rear Verti cal
Posi ti on Sensor . . . . . . . . . . . . . . . . . . . .8W-80-56
Memory Seat Recl i ner Motor . . . . . . . . . . . .8W-80-56
Memory Seat Recl i ner Posi ti on Sensor . . . .8W-80-56
Memory Seat/Mi rror Modul e - C1 . . . . . . . .8W-80-57
Memory Set Swi tch . . . . . . . . . . . . . . . . . . .8W-80-58
Message Center (LHD) . . . . . . . . . . . . . . . .8W-80-58
Message Center (RHD) . . . . . . . . . . . . . . . .8W-80-59
Mode Door Actuator . . . . . . . . . . . . . . . . . . .8W-80-59
Mul ti -Functi on Swi tch . . . . . . . . . . . . . . . . .8W-80-59
Needl e Movement Sensor . . . . . . . . . . . . . .8W-80-60
Output Shaft Speed Sensor . . . . . . . . . . . . .8W-80-60
Overhead Consol e . . . . . . . . . . . . . . . . . . . .8W-80-60
8W - 80 - 2 8W - 80 CONNECTOR PIN-OUTS NS/GS
Component Page
P30 J01D. . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-60
P50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-61
Park/Neutral Posi ti on Swi tch (EATX) . . . . .8W-80-61
Park/Neutral Posi ti on Swi tch (MTX). . . . . .8W-80-61
Passenger Ai rbag Squi b. . . . . . . . . . . . . . . .8W-80-61
Passenger Door Arm/Di sarm Swi tch . . . . . .8W-80-61
Passenger Door Courtesy Lamp. . . . . . . . . .8W-80-62
Passenger Door Lock Motor . . . . . . . . . . . . .8W-80-62
Passenger Door Lock Swi tch . . . . . . . . . . . .8W-80-62
Passenger Heated Seat Back . . . . . . . . . . . .8W-80-62
Passenger Heated Seat Cushi on . . . . . . . . .8W-80-62
Passenger Heated Seat Modul e . . . . . . . . . .8W-80-62
Passenger Heated Seat Swi tch . . . . . . . . . .8W-80-63
Passenger Power Mi rror C1. . . . . . . . . . . . .8W-80-63
Passenger Power Mi rror C2. . . . . . . . . . . . .8W-80-63
Passenger Power Seat Swi tch . . . . . . . . . . .8W-80-64
Passenger Power Wi ndow Swi tch . . . . . . . .8W-80-64
Passenger Seat Front Verti cal Motor . . . . . .8W-80-64
Passenger Seat Hori zontal Motor . . . . . . . .8W-80-64
Passenger Seat Rear Verti cal Motor . . . . . .8W-80-65
Passenger Seat Recl i ner Motor . . . . . . . . . .8W-80-65
Passenger Wi ndow Motor . . . . . . . . . . . . . .8W-80-65
Power Di stri buti on Center - C1 . . . . . . . . . .8W-80-65
Power Fol di ng Mi rror Swi tch . . . . . . . . . . .8W-80-68
Power Mi rror Swi tch . . . . . . . . . . . . . . . . . .8W-80-68
Power Seat Ci rcui t Breaker . . . . . . . . . . . . .8W-80-68
Powertrai n Control Modul e (Di esel ) . . . . . .8W-80-69
Powertrai n Control Modul e - C1 . . . . . . . . .8W-80-71
Powertrai n Control Modul e - C2 . . . . . . . . .8W-80-72
PRNDL Feed . . . . . . . . . . . . . . . . . . . . . . . .8W-80-72
PRNDL Swi tch . . . . . . . . . . . . . . . . . . . . . .8W-80-73
Radi ator Fan Di sconnect . . . . . . . . . . . . . . .8W-80-73
Radi ator Fan No. 1 . . . . . . . . . . . . . . . . . . .8W-80-73
Radi ator Fan No. 2 . . . . . . . . . . . . . . . . . . .8W-80-73
Radi ator Fan Rel ay (Gas) . . . . . . . . . . . . . .8W-80-73
Radi ator Fan Rel ay No. 1 (Di esel ). . . . . . . .8W-80-74
Radi o - C1 . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-74
Radi o - C2 . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-75
Component Page
Radi o - C3 . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-75
Radi o Choke . . . . . . . . . . . . . . . . . . . . . . . .8W-80-75
Rear A/C Heater Uni t . . . . . . . . . . . . . . . . .8W-80-75
Rear Bl ower Front Control Swi tch . . . . . . .8W-80-76
Rear Bl ower Rear Control Swi tch . . . . . . . .8W-80-76
Rear Ci gar Li ghter/Power Outl et. . . . . . . . .8W-80-76
Rear Dome Lamp . . . . . . . . . . . . . . . . . . . .8W-80-77
Rear Washer Motor . . . . . . . . . . . . . . . . . . .8W-80-77
Rear Wi per Motor . . . . . . . . . . . . . . . . . . . .8W-80-77
Reci rcul ati on Door Actuator . . . . . . . . . . . .8W-80-77
Remote Keyl ess Entry Modul e. . . . . . . . . . .8W-80-77
Ri ght Combi nati on Rel ay. . . . . . . . . . . . . . .8W-80-78
Ri ght Door Speaker . . . . . . . . . . . . . . . . . . .8W-80-78
Ri ght Fog Lamp (Bui l t-Up-Export) . . . . . . .8W-80-78
Ri ght Fog Lamp (Except Bui l t-Up-Export) .8W-80-78
Ri ght Front Panel Speaker . . . . . . . . . . . . .8W-80-78
Ri ght Front Park/Turn Si gnal Lamp
(Bui l t-Up-Export) . . . . . . . . . . . . . . . . . .8W-80-79
Ri ght Front Park/Turn Si gnal Lamp
Ri ght Front Speaker . . . . . . . . . . . . . . . . . .8W-80-79
Ri ght Front Wheel Speed Sensor . . . . . . . . .8W-80-79
Ri ght Headl amp (Bui l t-Up-Export) . . . . . . .8W-80-79
Ri ght Headl amp (Except Bui l t-Up-Export) .8W-80-80
Ri ght Headl amp Level i ng Motor
(Bui l t-Up-Export) . . . . . . . . . . . . . . . . . .8W-80-80
Ri ght Hi gh Headl amp (Chrysl er)
Ri ght Li ftgate Fl ood Lamp . . . . . . . . . . . . .8W-80-80
Ri ght Low Headl amp (Chrysl er)
Ri ght Mi d Readi ng Lamp . . . . . . . . . . . . . .8W-80-81
Ri ght Rear Door Ajar Swi tch . . . . . . . . . . . .8W-80-81
Ri ght Rear Lamp Assembl y
(Bui l t-Up-Export) . . . . . . . . . . . . . . . . . .8W-80-81
Ri ght Rear Lamp Assembl y
Ri ght Rear Pi l l ar Speaker . . . . . . . . . . . . . .8W-80-81
Ri ght Rear Readi ng Lamp . . . . . . . . . . . . . .8W-80-81
Ri ght Rear Sl i di ng Door Contacts . . . . . . . .8W-80-82
Ri ght Rear Speaker . . . . . . . . . . . . . . . . . . .8W-80-82
Ri ght Rear Vent Motor (LHD) . . . . . . . . . . .8W-80-82
Ri ght Rear Vent Motor (RHD) . . . . . . . . . . .8W-80-82
Ri ght Rear Wheel Speed Sensor . . . . . . . . .8W-80-82
Ri ght Repeater Lamp . . . . . . . . . . . . . . . . .8W-80-82
Ri ght Stop/Turn Si gnal Rel ay . . . . . . . . . . .8W-80-83
Ri ght Vi sor/Vani ty Mi rror Lamps . . . . . . . .8W-80-83
NS/GS 8W - 80 CONNECTOR PIN-OUTS 8W - 80 - 3
Component Page
Seat Bel t Swi tch . . . . . . . . . . . . . . . . . . . . .8W-80-83
Sentry Key I mmobi l i zer Modul e . . . . . . . . .8W-80-83
Speed Control Di mmi ng Modul e . . . . . . . . .8W-80-83
Stop Lamp Swi tch . . . . . . . . . . . . . . . . . . . .8W-80-83
Throttl e Posi ti on Sensor (2.0L) . . . . . . . . . .8W-80-84
Throttl e Posi ti on Sensor (Except 2.0L) . . . .8W-80-84
Tracti on Control Swi tch. . . . . . . . . . . . . . . .8W-80-84
Trai l er Tow Connector . . . . . . . . . . . . . . . . .8W-80-84
Transmi ssi on Control Modul e . . . . . . . . . . .8W-80-85
Component Page
Transmi ssi on Control Sol enoi ds. . . . . . . . . .8W-80-86
Transmi ssi on Range Sensor . . . . . . . . . . . . .8W-80-86
Turbi ne Speed Sensor . . . . . . . . . . . . . . . . .8W-80-87
Turbo Boost Pressure Sensor . . . . . . . . . . . .8W-80-87
Upstream Heated Oxygen Sensor . . . . . . . .8W-80-87
Vehi cl e Speed Control Servo . . . . . . . . . . . .8W-80-87
Vehi cl e Speed Sensor . . . . . . . . . . . . . . . . . .8W-80-88
Wi per Modul e (Bui l t-Up-Export) . . . . . . . . .8W-80-88
Wi per Modul e (Except Bui l t-Up-Export) . . .8W-80-88
8W - 80 - 4 8W - 80 CONNECTOR PIN-OUTS NS/GS
FUNCTION
-
-
-
CIRCUIT
-
-
-
M2 SPEED BLOWER MOTOR
GROUND
LOW SPEED BLOWER MOTOR
HIGH SPEED BLOWER MOTOR
CAV
1
2
3
4
5
6
7
8
9
10
C6 14LB
C104 12RD/WT
C5 16LG
Z1 12BK
C4 16TN
C107 12TN/BK
C7 12BK/TN
BLACK
1
6
5
10
A/C HEATER
CONTROL -C2
CLUTCH
COMPRESSOR
A/C
1
BLACK
2
Z1 18BK
C3 18DB/BK
2
1
CAV
GROUND
A/C COMPRESSOR CLUTCH RELAY OUTPUT
CIRCUIT FUNCTION
* BUILT-UP-EXPORT
PANEL LAMPS FEED E2 20OR*
CONTROL - C1
A/C HEATER
C61 22DB DUAL ZONE A/C ACTUATOR (+/-)
COMMON DOOR DRIVER C34 20DB/WT
21
10
11
1
BLUE
Z2 18BK/LG
C57 22DB/GY
C32 22GY/DB
C35 22DG/YL
C33 22DB/RD
D2 20WT/BK
C62 22DB/PK
D1 20VT/BR
C61 20DB
C34 22DB/WT
E2 20OR
V23 18BR/PK
C26 22PK/DB
C21 22DB/OR
C66 18BK/WT
C37 22YL
C36 22RD/WT
C102 22LG
C103 20DG/LB
V26 22YL/WT
C14 22WT/RD
21
20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
CAV
GROUND
SENSOR GROUND
RECIRCULATION DOOR DRIVER
MODE DOOR DRIVER
BLEND DOOR DRIVER
CCD(-)
DUAL ZONE A/C ACTUATOR (+/-)
CCD(+)
COMMON DOOR DRIVER
PANEL LAMPS FEED
5 VOLT SUPPLY
A/C SWITCH SENSE
WIPER DE-ICE SWITCHED GROUND
MODE DOOR FEEDBACK SIGNAL
BLEND DOOR FEEDBACK SIGNAL
ZONE DOOR FEEDBACK SIGNAL
A/C SWITCH SIGNAL
REAR WIPER SWITCH MUX
REAR DEFOGGER RELAY CONTROL
CIRCUIT FUNCTION
NS/GS 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 5
NSGS8005 J988W-3
FUNCTION
-
CIRCUIT
-
SENSOR GROUND
5 VOLT SUPPLY
AC PRESSURE SIGNAL
CAV
1
2
3
4
K4 18BK/LB
K6 18VT/WT
C18 18DB
FUNCTION
-
CIRCUIT
-
SENSOR GROUND
5 VOLT SUPPLY
A/C PRESSURE SIGNAL
CAV
1
2
3
4
K4 20BK/LB
K7 20OR
C18 20DB
GRAY
2 1
4 3
FUNCTION CIRCUIT
SENSOR GROUND
ZONE DOOR FEEDBACK SIGNAL
5 VOLT SUPPLY
CAV
1
2
3
4
5
C61 20DB
C57 20DB/GY
C102 20LG
C26 20PK/DB
C62 20DB/PK
NATURAL
1 5
FUNCTION CIRCUIT
PASSENGER AIRBAG LINE NO. 1
DRIVER AIRBAG LINE NO. 1
DRIVER AIRBAG LINE NO. 2
CAV
1
2
3
4
R42 18BK/YL
R44 18DG/YL
R43 18BK/LB
R45 18DG/LB
1
3
2
4
GRAY
1 4
YELLOW
A/C
PRESSURE
TRANSDUCER
(GAS)
A/C
ZONE DOOR
ACTUATOR
AIRBAG
CONTROL
MODULE - C1
(DIESEL)
TRANSDUCER
PRESSURE
A/C
10
5
6
1
(DIESEL)
SENSOR
- -
- -
- -
- -
CIRCUIT FUNCTION CAV
1
2
3 K4 20BK/LB SENSOR GROUND
6
K151 20WT LOW IDLE POSITION SWITCH 5
4
ACCELERATOR PEDAL SENSOR SIGNAL K22 20OR/DB 7
8 K167 20BR/YL
9
K6 20VT/WT 10
ACCELERATOR
PEDAL POSITION
- -
ACCELERATOR PEDAL SENSOR GROUND
5 VOLT SUPPLY
BLACK
(DUAL ZONE A/C)
8W - 80 - 6 8W-80 CONNECTOR PIN-OUTS NS/GS
J988W-3 NSGS8006
FUNCTION
-
-
-
-
-
-
-
CIRCUIT
-
-
-
-
-
-
-
CCD BUS(+)
CCD BUS(-)
AIRBAG WARNING LAMP DRIVER
GROUND
CAV
1
2
3
4
5
6
7
8
9
10
11
12
13
F14 18LG/YL
F23 18 DB/YL
D1 20VT/BR
D2 20WT/BK
R41 18BK/TN
Z2 18BK/LG
7
BLACK
FUNCTION CIRCUIT
AMBIENT TEMPERATURE SENSOR SIGNAL
SENSOR GROUND
CAV
1
2
G31 20VT/LG
G32 20BK/LB
GRAY
2 1
FUNCTION CIRCUIT
GROUND
BACK-UP LAMP FEED
CAV
1
2
Z1 18BK
L1 18VT/BK
GRAY
2 1
13
1 6
2 1
GROUND
BACK-UP LAMP FEED
CIRCUIT
Z1 18BK
L1 18VT/BK
CAV
2
1
FUNCTION
GRAY
AIRBAG
CONTROL
MODULE - C2
ALL WHEEL
DRIVE
SOLENOID - C1
(3.8L ONLY)
AMBIENT AIR
TEMPERATURE
SENSOR
(3.8L ONLY)
SOLENOID - C2
DRIVE
ALL WHEEL
NSGS8007 J988W-3
FUNCTION CIRCUIT
GROUND
BACK-UP LAMP FEED
CAV
1
2
3
V23 18BR/PK
Z1 20BK
L1 20VT/BK
1
RED
2
1 7
FUNCTION CIRCUIT
GROUND
PANEL LAMPS FEED
CAV
1
2
Z1 18BK
E2 18OR
P112 20YL/WT* 4
P114 20YL/BK* 5
- 6
L24 20WT/LG* 7
-
BLACK
POWER MIRROR B(-)
POWER MIRROR B(-)
AUTOMATIC HEADLAMP SIGNAL
ASH
RECEIVER
LAMP
(LHD)
AUTOMATIC
DAY/NIGHT
MIRROR
(RHD)
LAMP
RECEIVER
ASH
* EXCEPT BUILT-UP-EXPORT
-
E2 18OR
2
1
CAV
-
PANEL LAMPS FEED
CIRCUIT FUNCTION
3 1
3 Z1 18BK GROUND
RED
J988W-3 NSGS8008
CIRCUIT CAV
1
2
3
4
Z1 12BK
A2 12PK/BK
F35 14RD
F20 20WT
CIRCUIT

-
CAV
1
2
3
4
Z1 14BK
Z1 20BK
A2 12PK/BK
F35 14RD

BLACK
1
3
2
4
BLACK
1 2
4 3
B09
S02
CIRCUIT
-
CAV
1
2
3
4
5
6
7
8
9
10
11
12
L50 18WT/TN
M11 20PK/LB
G78 18TN/BK
L77 20BR/LB
P98 20WT/RD
V13 18BR/LG
V23 18BR/PK
F133 20BR/RD
F136 20VT/WT
Z1 12BK
C15 12BK/WT
CIRCUIT
-
CAV
1
2
3
4
5
6
7
8
9
10
11
12
L50 20WT/TN
M11 20PK/LB
G78 18TN/BK
L77 20BR/LB
P98 20WT/RD
V13 18BR/LG
V23 18BR/PK
F133 20BR/RD
F136 20VT/WT
Z1 12BK
C15 12BK/WT
BLACK
7
14
1
8
BLACK
7
14
1
8
B17 LJ01
CIRCUIT CAV
1
2
3
4
Z1 14BK
L1 20VT/BK
G4 18DB
A141 16DG/WT
CIRCUIT CAV
1
2
3
4
Z1 16BK
L1 20VT/BK
G4 18DB
A141 16DG/WT
LT. GRAY
1 4
LT. GRAY
1 4
B13 AW4
HS5D
B09
3 4
2 1
BLACK
4
2
3
1
BLACK
F20 20WT
F35 14RD
Z1 14BK
Z1 14BK
4
3
2
1
CAV CIRCUIT
F20 20WT
A2 12PK/BK
F35 14RD
Z1 12BK
4
3
2
1
CAV CIRCUIT
F35 14RD
A2 12PK/BK
NSGS8009 J988W-3

CIRCUIT

CAV
B1
B2
B3
B4
B5
B6

B12
B13
B14

B16
B17
B18
B19
B20
B21
B22
B23
B24
B25
B26
B27
B28
B29
B30
B31
B32
B33
B34
B35
B36
V16 20WT

L44 20VT/RD
A1 12RD
M20 20BR

D1 18VT/BR
D2 18WT/BK
D6 20PK/LB*

D20 20LG*
D21 20PK
L34 20RD/OR
Z39 20BK
L94 20OR/WT
L324 20WT/LG
M13 20BK/YL
F14 18LG/YL
F23 18DB/YL

C104 12RD/WT
C107 12TN/BK
C4 16TN
C6 14LB
C5 16LG
C71 12DB
C103 20DG/LB
B7
B8
B9
B10
B11
B15
P70 20WT*
P71 20YL*
P72 20YL/BK*
P73 20YL/PK*
P74 20DB*
P75 20DB/WT*
A7
A36
A1
A30
BLACK
B7
B36
B1
B30
CIRCUIT

-
CAV
1
2
3
4
5
6

12
13
14

16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
V16 20WT

L44 20VT/RD
A1 12RD
M20 20BR

P70 20WT*
P70 20WT**
P71 20YL*
P71 20YL**
P72 20YL/BK*
P72 20YL/BK**
P73 20YL/PK*
P73 20YL/PK**
P74 20DB*
P74 20DB**
D1 20VT/BR
D2 20WT/BK
D6 20PK/LB*
P75 20DB/WT*
P75 20DB/WT**
D20 20LG*
D21 20PK
L34 20RD/OR
Z39 18BK
L94 20OR/WT
L324 22WT/LG
M13 20BK/YL
F14 18LG/YL
F23 18DB/YL

C104 12RD/WT
C107 12TN/BK
C4 16TN
C6 14LB
C5 16LG
C71 12DB
C103 20DG/LB
7
8
9
10
11
15

GRAY
1
8
15
19
23
30
7
14
18
22
29
36
X153 20WT/BR X153 20WT/BR
X154 20WT/VT X154 20WT/VT
M20 20BR
X155 20BR/WT
X156 20VT/WT X156 20VT/WT
X155 20BR/WT
P18
B23
L44 20VT/RD
Z39 20BK
L36 20LG
L36 20LG
L36 20LG
L77 18BR/YL L77 18BR/YL
F39 18PK/LG*
F39 18PK/LG*
L39 18LB B3 L39 18LB 3
F14 20LG/YL
F23 20DB/YL
* GAS
** GAS/MEMORY OPTIONS
GAS, EXCEPT BUILT-UP-EXPORT
BUILT-UP-EXPORT
J988W-3 NSGS8010

CIRCUIT

-
-

-
CAV
1
2
3
4
5
6
7
8
9
10
11

16
17
18
19
20
21

24
25
26
27
28
29
30
31
32
33
34
35
36

B27 20RD/YL
G3 20BK/PK
G19 20LG/OR
G19 20LG/OR

X57 20BR/LB
X58 20DB/OR
X51 20BR/YL
X52 20DB/WT
X15 16BK/DG
X53 20DG
X53 20DG*
X54 20VT
X54 20VT*
X55 20BR/RD
X55 20BR/RD*
X56 20DB/RD
X56 20DB/RD*

V37 20RD/LG
F30 16RD
G96 20LG/RD
G96 20LG/RD
Z11 20BK/WT
P66 20WT/BK
P65 20DB/YL
P64 20YL/OR
P69 20WT/RD
P68 20DG/RD
P67 20YL/RD
C50 12BK/LG*

C60 16BK/LB*
C70 12DG*
12
13
14
15
22
23
CIRCUIT

-
-

-

CAV
A1
A2
A3
A4
A5
A6
A7
A8
A9
A10
A11
A13
A14
A15
A16
A17
A18
A19
A20
A21

A24
A25
A26
A27
A28
A29
A30
A31
A32
A33
A34
A35
A36

B27 18RD/YL
G3 18BK/PK
G19 18LG/OR

X57 20BR/LB
X58 20DB/OR
X51 20BR/YL
X52 20DB/WT
X15 16BK/DG
X53 20DG
X54 20VT
X55 20BR/RD
X56 20DB/RD

V37 20RD/LG
F30 16RD
Z11 20BK/WT
P66 20WT/BK**
P65 20DB/YL**
P64 20YL/OR**
P69 20WT/RD**
P68 20DG/RD**
P67 20YL/RD**
C50 12BK/LG*

C60 16BK/LB*
C60 16BK/LB*
C34 20DB/WT*
C70 12DG*
C61 20DB*
A12

GRAY
1
8
15
19
23
30
7
14
18
22
29
36
A7
A36
A1
A30
BLACK
B1
B36
B7
B30
A22
A23
F30 16RD
P34
B23
L13 20BR/YL
L13 18BR/YL
L13 20BR/YL
K29 20WT/PK K29 20WT/PK
V32 20YL/RD V32 20YL/RD
V30 20DB/RD
L50 18WT/TN
F32 18PK/DB
V30 20DB/RD
L50 18WT/TN
F32 18PK/DB
G96 20LG/RD**
C34 20DB/WT*
C61 20DB*
GAS,BUILT-UP-EXPORT
GAS
BUILT-UP-EXPORT
RHD
DIESEL
* REAR A/C HEATER
** MEMORY SEAT
B27 20RD/YL A1
A2 G3 20BK/PK
G85 20OR/BK A17 17 G85 20OR/BK
P114 20YL/BK A18
18 P114 20YL/BK
P112 20YL/WT A20 20 P112 20YL/WT
G96 20LG/RD**
G96 20LG/RD** A23
C63 20LB* A34 C63 22LB 34
NSGS8011 J988W-3

(GAS)
B33
(GAS)
E36
5 F20 18WT
6
1
10
5
BLACK
6
1
10
5
BLACK
L1 18VT/BK
G6 16GY
F11 18RD/WT
D1 18VT/BR
D6 18PK/LB
D21 18PK
D20 18LG
D2 18WT/BK
K4 18BK/LB
10
9
8
7
6
4
3
2
1
CAV CIRCUIT
L1 20VT/BK
G6 20GY
F11 20RD/WT
D1 18VT/BR
D6 20PK/LB
F20 20WT
D21 20PK
D20 20LG
D2 18WT/BK
K4 20BK/LB
10
9
8
7
6
5
4
3
2
1
CAV CIRCUIT
(DIESEL)
B33
(DIESEL)
E120
5 F20 20WT 6
1
10
5
BLACK
L1 18VT/BK
K3 20BK/VT
K9 18LB
K1 18DG/RD
K21 18BK/RD
A141 18DG/WT
G58 20BK/YL
G18 20BK/PK
G6 16GY
10
9
8
7
6
4
3
2
1
CAV CIRCUIT CAV
2
3
4
5
1
CIRCUIT
G6 20GY
G18 20PK/BK
G58 20BK/YL
A141 16DG/WT
F20 20WT
7
6
8
10
9
K21 20BK/RD
K1 20DG/RD
K9 20LB
K3 20BK/VT
L1 20VT/BK
BLACK
1
6
5
10
S02 B56
CIRCUIT CAV
1
2
3
4
Z1 12BK
A2 12PK/BK
F20 20WT
CIRCUIT CAV
1
2
3
4
Z1 14BK
A2 12PK/BK
BLACK
1
3
2
4
BLACK
1 2
4 3
F35 14RD
Z1 20BK*
F35 14RD
F20 20WT
* MEMORY
F20 20WT
F35 14RD
F35 14RD
3 4
2 1
BLACK
4
2
3
1
BLACK
Z1 14BK
4
3
2
1
CAV CIRCUIT
F20 20WT
Z1 12BK
4
3
2
1
CAV CIRCUIT
B56 HS5P
F35 14RD
- -
J988W-3 NSGS8012

6
1
10
5
10
5
6
1
GRAY
LIGHT
K141 18TN/WT
Z11 18BK/WT
V37 18RD/LG
K29 18WT/PK
V30 18DB/RD
G3 18BK/PK
V32 18YL/RD
A142 18DG/OR
C103 18DG/LB
10
9
8
7
6
5
4
3
2
1
CAV
-
CIRCUIT
K141 20TN/WT
Z11 20BK/WT
V37 20RD/LG
K29 20WT/PK
V30 20DB/RD
G3 20BK/PK
V32 20YL/RD
A142 18DG/OR
C103 20DG/LB
10
9
8
7
6
5
4
3
2
1
CAV
-
CIRCUIT
B70 E43
C20 B75
BLUE
BLUE
Z2 18BK/LG
G31 20VT/LG
V23 18BR/PK
Z1 20BK
L1 20VT/BK
G74 18TN/RD
F133 20BR/YL
F136 20VT/YL
E2 18OR
L24 20WT/LG**
P112 20YL/WT**
P114 20YL/BK**
12
14
15
16
17
13
19
20
18
12
14
15
16
17
13
19
20
18
Z1 20BK
L1 20VT/BK
G74 18TN/RD
F133 20BR/YL
F136 20VT/YL
E2 20OR
P114 20YL/BK**
P112 20YL/WT**
L24 20WT/LG**
7
9
10
11
8 G32 20BK/LB
7
9
10
11
8 G32 20BK/LB
Z2 18BK/LG
G31 20VT/LG
V23 18BR/PK
1
11
10
20
11
10
20
1
D1 18VT/BR
D2 18WT/BK
M113 20LB/PK
M13 20BK/YL
F41 20PK/VT
M20 20BR
6
5
4
3
2
1
CAV CIRCUIT
D1 18VT/BR
D2 18WT/BK
M113 20LB/PK
M13 20BK/YL
F41 20PK/VT
M20 20BR
6
5
4
3
2
1
CAV CIRCUIT
G10 18LG/RD*
G75 18TN* 14
G10 18LG/RD*
* RHD
LIGHT
GRAY
NSGS8013 J988W-3

Z1 20BK
L50 18WT/TN
3
6
1
4
BLACK BLACK
4
1
6
3
L63 18DG/RD
6
5
1
Z1 18BK
Z1 20BK
L50 18WT/TN
L50 18WT/TN
L77 20BR/LB
L1 20VT/BK
L63 18DG/RD
L63 18DG/RD
4
3
2
CAV
-
CIRCUIT
6
5
1
L77 20BR/LB
L1 20VT/BK
4
3
2
CAV
-
CIRCUIT
3
6
1
4
BLACK BLACK
4
1
6
3
Z1 20BK
L78 20DG/YL
L62 18BR/RD
6
4
1
Z1 18WT
Z1 20BK
L50 18WT/TN
L78 18BR
L78 20DG/YL
L1 20VT/BK
L62 18BR/RD
L62 18BR/RD
5
3
2
CAV
-
CIRCUIT
6
4
1
L50 18WT/TN
L1 20VT/BK
5
3
2
CAV
-
CIRCUIT
B99
(TRAILER TOW)
(TRAILER TOW)
B98 T08
T05
DOOR ACTUATOR
BLEND
2 1
BACK-UP
SWITCH
BACK-UP LAMP FEED L1 18VT/BK 2
F20 20WT* FUSED IGNITION SWITCH OUTPUT
FUSED IGNITION SWITCH OUTPUT F20 18WT
1
1
CAV FUNCTION CIRCUIT
* DIESEL
FUNCTION CIRCUIT
BLEND AIR DOOR DRIVER
5 VOLT SUPPLY
BLEND DOOR FEEDBACK SIGNAL
SENSOR GROUND
BLEND AIR DOOR DRIVER
CAV
1
2
3
4
5
C33 20DB/RD
C26 20PK/DB
C36 20RD/WT
C57 20DB/GY
C34 20DB/WT
NATURAL
1 5
J988W-3 NSGS8014

M20 20BR
G75 18TN
G10 18LG/RD
G76 18TN/YL
V14 18RD/VT
G78 18TN/BK
G29 20BK/TN
P96 20WT/LG
G6 20GY
V20 20BK/WT
V13 18BR/LG
G74 18TN/RD
G77 18TN/OR
G4 18DB
P97 20WT/DG
P98 20WT/RD
G70 18BR/TN
V7 20DG/WT
80
79
78
77
76
75
74
73
72
71
70
69
68
67
66
65
64
63
62
61
60
59
58
57
56
55
54
53
52
51
50
49
48
47
46
45
44
43
42
41
CAV
COURTESY LAMP GROUND
DRIVER DOOR AJAR SWITCH SENSE
SEAT BELT SWITCH SENSE
RIGHT REAR DOOR AJAR SWITCH SENSE
WIPER ON/OFF RELAY CONTROL
LIFTGATE AJAR SWITCH SENSE
WASHER FLUID SWITCH SENSE
PASSENGER DOOR SWITCH MUX
ENGINE OIL PRESSURE SWITCH SENSE
REAR WASHER MOTOR CONTROL
REAR WIPER MOTOR CONTROL
PASSENGER DOOR AJAR SWITCH SENSE
LEFT REAR DOOR AJAR SWITCH SENSE
FUEL LEVEL SENSOR SIGNAL
DRIVER DOOR SWITCH MUX
LIFTGATE LOCK/UNLOCK MUX
HOOD AJAR SWITCH SENSE
WIPER PARK SWITCH SENSE
-
-
-
-
-
-
-
-
-
-
-
-
CIRCUIT
-
-
-
-
-
-
-
-
-
-
-
-
FUNCTION
G7 18WT/OR*
V38 20LB/RD*
G18 20PK/BK*
G58 20BK/YL* ENGINE COOLANT TEMPERATURE SENSOR SIGNAL
G55 20OR/BK* ENGINE DISABLE SIGNAL
POWER MIRROR FOLD RELAY P171 20VT/WT
P174 20YL/RD POWER MIRROR UNFOLD RELAY
ENGINE SPEED SENSOR SIGNAL K159 20VT/RD*
BODY
CONTROL
MODULE - C1
NATURAL
80
70
60
50
71
61
51
41
L24 20WT/LG**
L193 20OR/WT**
* DIESEL
** GAS
BUILT-UP-EXPORT
VEHICLE SPEED SENSOR SIGNAL
AUTOMATIC HEADLAMP SIGNAL
SPEED CONTROL LAMP DRIVER
COOLANT LEVEL SWITCH SENSE
LOW BEAM RELAY CONTROL
NSGS8015 J988W-3

X3 20BK/RD HORN RELAY CONTROL
L110 22BK/YL AUTO HEADLAMP SWITCH SENSE
B A
BLACK
40
30
20
10
31
21
11
NATURAL
1
Z1 20BK
G9 20GY/BK
B
A
CAV
GROUND
RED BRAKE WARNING LAMP DRIVER
CIRCUIT FUNCTION
L308 20LG/WT
V26 22YL/WT
D9 22GY/BK
D2 20WT/BK
G6 22GY
G19 20LG/OR
G69 22BK/OR
Z2 20BK/LG
L307 20LG/OR
E17 20YL/BK
Z2 20BK/LG
Z20 20BK/WT**
E92 22OR/BK
V52 20DG/YL
G2 22VT
G26 20LB
D1 20VT/BR
M32 22BK/LB
G96 20LG/RD
40
39
38
37
36
35
34
33
32
31
30
29
28
27
26
25
24
23
22
21
20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
CAV
PARK LAMP SWITCH SENSE
REAR WIPER SWITCH MUX
RKE MODULE PROGRAM ENABLE
CCD BUS(-)
ABS WARNING LAMP DRIVER
VTSS LAMP DRIVER
GROUND
HEADLAMP SWITCH SENSE
STEP DIMMER SWITCH SENSE
GROUND
GROUND
DIMMER SWITCH SIGNAL
FRONT WIPER SWITCH MUX
ENGINE TEMPERATURE WARNING LAMP DRIVER
KEY-IN IGNITION SWITCH SENSE
CCD BUS(+)
COURTESY LAMP SWITCH SENSE
RKE INTERFACE
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
CIRCUIT
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
FUNCTION
P136 20YL POWER FOLDING MIRROR SWITCH SIGNAL
* BUILT-UP-EXPORT
GAS
BODY
CONTROL
MODULE - C2
BRAKE PRESSURE
SWITCH
J988W-3 NSGS8016
V23 18BRPK
Z1 20BK
L1 20VT/BK
P112 20YL/WT*
P114 20YL/BK*
L24 20WT/LG* L24 20WT/LG*
P114 20YL/BK*
3
4
1
6
3
4
1
6
EC1 C19
5
6
4
3
2
1
CAV CIRCUIT CIRCUIT CAV
V23 18BRPK 1
2
3
Z1 20BK
L1 20VT/BK
4 P112 20YL/WT*
6
5
BLACK
FUNCTION
- -
CENTER DOME LAMP GROUND
CENTER DOME LAMP FEED
CIRCUIT CAV
1
2 M113 20LB/PK
M20 20BR 3
3 1
3 1
RED
3 1
BLACK
L50 20WT/TN
Z1 20BK
3
2
1
CAV
STOP LAMP SWITCH OUTPUT
GROUND
-
FUNCTION
-
CIRCUIT
K44 18TN/YL
K4 18BK/LB
K7 18OR
3
2
1
CAV
CAMSHAFT POSITION SENSOR SIGNAL
SENSOR GROUND
8 VOLT SUPPLY
CIRCUIT FUNCTION
CENTER DOME
LAMP
CENTER HIGH
MOUNTED STOP
LAMP
SENSOR
POSITION
CAMSHAFT
NSGS8017 J988W-3

GROUND Z1 20BK
SWITCH
(DIESEL)
CLUTCH
RED
CLUTCH SWITCH
K119 20LG/BK 1
2
1 2
IGNITION SWITCH OUTPUT (START) T141 20YL/RD 2
1 F45 20YL/RD
FUSED B(+) ENGINE STARTER MOTOR RELAY
BLACK
1 2
4
NATURAL
1
V37 20RD/LG
Z2 20BK/LG
X3 20BK/RD
4
3
2
1
CAV
SPEED CONTROL SWITCH SIGNAL
GROUND
HORN RELAY DRIVER
-
CIRCUIT
-
FUNCTION
1 2
YELLOW
R45 18DG/LB
R43 18BK/LB
2
1
CAV
DRIVER AIRBAG LINE NO.2
DRIVER AIRBAG LINE NO.1
CIRCUIT FUNCTION
CLOCKSPRING - C2
CLOCKSPRING - C1
2 1
BLACK
1
2 T141 20YL/RD IGNITION SWITCH OUTPUT (START)
CLUTCH
INTERLOCK
SWITCH
(MTX)
CLUTCH
INTERLOCK
SWITCH
JUMPER
(EATX)
T141 20YL/RD IGNITION SWITCH OUTPUT (START)
J988W-3 NSGS8018

3 1
BLACK
9
8
7
1
25
24
23
16
17
10
NATURAL
K24 18GY/BK
K4 18BK/LB
K7 18OR
3
2
1
CAV
CRANKSHAFT POSITION SENSOR SIGNAL
SENSOR GROUND
8 VOLT SUPPLY
CIRCUIT FUNCTION
A10 12RD/DG
Z7 12BK
F20 18WT
B27 18RD/YL
D1 18VT/BR
D2 18WT/BK
B6 18WT/DB
B2 18YL
G19 18LG/OR
L50 18WT/TN
B8 18RD/DB
B4 18LG
A20 12RD/DB
Z7 12BK
B9 18RD
B7 18WT
B3 18LG/DB
B1 18YL/DB
25
24
23
22
21
20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
CAV
FUSED B(+)
GROUND
TRACTION CONTROL SWITCH SENSE
CCD BUS (+)
CCD BUS (-)
RIGHT FRONT WHEEL SPEED SENSOR (-)
RIGHT REAR WHEEL SPEED SENSOR (+)
STOP LAMP SWITCH SENSE
LEFT FRONT WHEEL SPEED SENSOR (-)
LEFT REAR WHEEL SPEED SENSOR (+)
FUSED B(+)
GROUND
LEFT FRONT WHEEL SPEED SENSOR (+)
RIGHT FRONT WHEEL SPEED SENSOR (+)
LEFT REAR WHEEL SPEED SENSOR (-)
RIGHT REAR WHEEL SPEED SENSOR (-)
-
-
-
-
-
-
-
FUNCTION
-
-
-
-
-
-
-
CIRCUIT
1 2
CRANK CASE
HEATER
(DIESEL)
GROUND Z1 18BK 2
1 A141 18DG/WT
FUEL PUMP RELAY OUTPUT
BRAKE
ANTI-LOCK
CONTROLLER
SENSOR
POSITION
CRANKSHAFT
BLACK*
* DIESEL
NSGS8019 J988W-3

6
1
10
5
BLACK
X156 20VT/WT**
X155 20BR/WT*
X54 20VT**
X53 20DG*
X56 20DB/RD**
X55 20BR/RD*
P24 20PK/WT
P23 20PK/RD
X154 20WT/VT**
X153 20WT/BR*
P22 20PK/BK
M11 20PK/LB
X13 16RD/DG
X15 16BK/DG
10
8
7
6
5
5
4
3
2
1
CAV CIRCUIT
6
1
10
5
BLACK
X156 20VT/WT**
X155 20BR/WT*
X54 20VT**
X53 20DG*
X56 20DB/RD**
X55 20BR/RD*
P24 20PK/WT
P23 20PK/RD
X154 20WT/VT**
X153 20WT/BR*
P22 20PK/BK
M11 20PK/LB
X13 16RD/DG
X15 16BK/DG
4
3
2
1
CAV CIRCUIT
D02 B01
B02 D01D
CIRCUIT CAV
1
2
3
4
5
7
8
10
11
12
13
14
Q13 18DB
Q14 18GY
Z2 20BK/LG
E2 20OR
F131 20BK/PK
F55 12TN/DG
Q23 18RD/WT
Z1 12BK
P97 20WT/DG
F133 20BR
Q24 18DG
F21 16TN
BLACK
7
14
1
8
CIRCUIT CAV
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Q13 18DB
Q14 18GY
Z2 20BK/LG
E2 20OR
F131 20BK/PK
Q26 14VT/RD
F55 14TN/DG
Q23 18RD/WT
Q16 14BR/WT
Z1 12BK
P97 20WT/DG
F133 20BR
Q24 18DG
F21 16TN
BLACK
7
14
1
8
8
9
9
10 10
9
9
8
5
5
6
7
8
10
8
1
14
7
BLACK
X13 16RD/DG
Q16 12BR/WT
F55 12TN/DG
E2 20OR
F133 20BR
F136 20VT/YL
X54 20VT*
X56 20DB/RD*
M11 20PK/LB
Z1 18BK
P96 20WT/LG
Z2 20BK/LG
Q26 12VT/RD
X15 16BK/DG
14
13
12
11
10
9
8
7
6
5
4
3
2
1
CAV CIRCUIT
8
1
14
7
BLACK
X13 16RD/DG
Q16 12BR/WT
F55 12TN/DG
E2 20OR
F136 20VT/YL
X54 20VT*
X56 20DB/RD*
M11 20PK/LB
Z1 20BK
P96 20WT/LG
Z2 20BK/LG
Q26 12VT/RD
X15 16BK/DG
14
13
12
11
9
8
7
6
5
4
3
2
1
CAV CIRCUIT
X55 20BR/RD** 7
X53 20DG** 8
F133 20BR 10
7 X55 20BR/RD**
8 X53 20DG**
** RHD
* LHD
B03
D01P
6 Q26 12VT/RD
Q16 12BR/WT 9
J988W-3 NSGS8020

(RHD)
(LHD)
X154 20WT/VT
X156 20VT/WT
X153 20WT/BR
X155 20BR/WT
6
1
10
5
BLACK
-
10
9
8
7
6
5
4
3
2
1
CAV CIRCUIT
6
1
10
5
BLACK
X156 20VT/WT
X154 20WT/VT
-
10
9
8
7
6
5
4
3
2
1
CAV CIRCUIT
D02 B120
(LHD)
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
(RHD)
B120 D02
CIRCUIT CAV
1
2
3
4
5
6
7
8
9
10
-
X153 20WT/BR
X155 20BR/WT
BLACK
5
10
1
6
CIRCUIT CAV
1
2
3
4
5
6
7
8
9
10
-
BLACK
5
10
1
6
NSGS8021 J988W-3

CIRCUIT
-
-
-
-
-
-
-
-
FUNCTION
-
-
-
-
-
-
-
-
CCD BUS(+)
GROUND
GROUND
SCI RECEIVE
SCI TRANSMIT
CCD BUS(-)
SCI RECEIVE (EATX)
FUSED B(+)
CAV
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
D1 20VT/BR
Z2 20BK/LG
Z11 20BK/WT
D20 20LG
D21 20PK
D2 20WT/BK
D6 20PK/LB
M1 20PK
1 8
9 16
BLACK
CONNECTOR
DATA LINK
CIRCUIT FUNCTION
GROUND
AUTOMATIC SHUT DOWN RELAY OUTPUT
SENSOR GROUND
HEATED OXYGEN SENSOR 1/2 SIGNAL
CAV
1
2
3
4
Z12 20BK/TN
A142 18DG/OR
K4 20BK/LB
K141 20TN/WT
1 2
3 4
BLACK
OXYGEN SENSOR
DOWNSTREAM HEATED
COURTESY LAMP
DRIVER DOOR
SWITCH
ARM/DISARM
DRIVER DOOR
2 1
BLACK
2 1
BLACK
Z1 20BK
M11 20PK/LB
2
1
CAV
GROUND
FUNCTION CIRCUIT
P97 20WT/DG
Z2 20BK/LG
2
1
CAV
GROUND
FUNCTION CIRCUIT
J988W-3 NSGS8022

LOCK SWITCH
DRIVER DOOR
1 3
BLACK
3
2
1
Z2 20BK/LG*
Z2 20BK/LG
P97 20WT/DG*
P97 20WT/DG
E2 20OR
E2 20OR
CAV
GROUND
PANEL LAMPS FEED
CIRCUIT FUNCTION
DRIVER DOOR
LOCK MOTOR
2 1
BLACK
F133 20BR
F131 20BK/PK
2
1
CAV
LOCK RELAY OUTPUT
LEFT FRONT UNLOCK RELAY OUTPUT
CIRCUIT FUNCTION
FUNCTION CIRCUIT
HEATED SEAT DRIVER
GROUND
CAV
A
B
P88 18RD/WT
Z1 18BK
SEAT BACK
DRIVER HEATED
FUNCTION CIRCUIT
HEATED SEAT DRIVER
HEATED SEAT DRIVER
CAV
P87 18RD/WT
P88 18RD/WT
P89 20BK/RD
Z1 18BK
A
B
C
DRIVER HEATED
SEAT CUSHION
D
HEATED SEAT BACK
GROUND
FUSED B(+)
DRIVER HEATED SEAT SWITCH
D
SEAT MODULE
DRIVER HEATED
C
B
A
F35 18RD
P7 20WT/BK
P86 20VT
P87 18RD/WT
CAV
HEATED SEAT TEMPERATURE SENSOR
DRIVER HEATED SEAT SWITCH
CIRCUIT FUNCTION
P89 20BK/RD E HEATED SEAT BACK
F Z1 18BK GROUND
* RKE
NSGS8023 J988W-3

* BUILT-UP-EXPORT
MIRROR - C2
DRIVER POWER
MIRROR - C1
DRIVER POWER
DRIVER POWER MIRROR FOLD P160 20LB*
DRIVER POWER MIRROR UNFOLD P159 20DG*
4
6
5
P114 20YL/BK** POWER MIRROR B(-)
RED
5 6 4
1 2 3
4 5 6
1 2 3
BLUE
P65 20DB/YL
P69 20WT/RD
P64 20YL/OR
3
2
1
CAV
DRIVER POWER MIRROR LEFT/RIGHT
DRIVER POWER MIRROR RETURN
DRIVER POWER MIRROR UP/DOWN
CIRCUIT FUNCTION
Z1 20BK
C16 20LB/YL
P73 20YL/PK
P71 20YL
P75 20DB/WT
6
5
4
3
2
1
CAV
GROUND
REAR DEFOGGER LAMP DRIVER
DRIVER POWER MIRROR RIGHT/DOWN
DRIVER POWER MIRROR LEFT
DRIVER POWER MIRROR UP
CIRCUIT FUNCTION
POWER MIRROR B(-) P112 20YL/WT
-
D
SEAT SWITCH
DRIVER HEATED
C
B
A
F20 20WT
-
F20 20WT
P86 20VT
CAV
CIRCUIT FUNCTION
Z1 18BK E GROUND
F P7 20WT/BK DRIVER HEATED SEAT BACK
J988W-3 NSGS8024

WINDOW SWITCH
DRIVER POWER
8
1
14
7
NATURAL
E2 20OR
Z1 12BK
F21 16TN
F55 14TN/DG
Q11 16LG
Q23 18RD/WT
Q21 16WT
Q14 18GY
Q16 14BR/WT
Q13 18DB
Q26 14VT/WT
Q24 18DG
14
13
12
11
10
9
8
7
6
5
4
3
2
1
CAV
PANEL LAMPS FEED
GROUND
FUSED IGNITION SWITCH OUTPUT (RUN/ACC)
-
-
CIRCUIT
-
-
FUNCTION
SEAT SWITCH
DRIVER POWER
CIRCUIT FUNCTION
GROUND
DRIVER SEAT RECLINER SWITCH DOWN
DRIVER POWER SEAT HORIZONTAL REARWARD
DRIVER SEAT RECLINER SWITCH UP
FUSED B(+)
DRIVER POWER SEAT HORIZONTAL FORWARD
DRIVER POWER SEAT FRONT UP
DRIVER POWER SEAT REAR UP
DRIVER POWER SEAT REAR DOWN
DRIVER POWER SEAT FRONT DOWN
CAV
1
2
3
4
5
6
7
8
9
10
Z1 14BK
P43 14GY/LB
P17 14RD/LB
P41 14GY/WT
F35 14RD
P15 14YL/LB
P19 14YL/LG
P11 14YL/WT
P13 14RD/WT
P21 14RD/LG
GREEN
1 5
6 10
HORIZONTAL MOTOR
DRIVER SEAT
FUNCTION CIRCUIT
DRIVER POWER SEAT HORIZONTAL FORWARD
DRIVER POWER SEAT HORIZONTAL REARWARD
CAV
A
B
P15 14YL/LB
P17 14RD/LB
B A
BLACK
MOTOR
FRONT VERTICAL
DRIVER SEAT
FUNCTION CIRCUIT
DRIVER POWER SEAT FRONT DOWN
DRIVER POWER SEAT FRONT UP
CAV
A
B
P21 14RD/LG
P19 14YL/LG
B A
BLACK
FUSED B(+)
LEFT WINDOW DRIVER (UP)
POWER WINDOW LEFT REAR B(+) DOWN
LEFT FRONT WINDOW DRIVER (DOWN)
POWER WINDOW RIGHT REAR B(+) UP
MASTER WINDOW SWITCH RIGHT FRONT UP
POWER WINDOW LEFT REAR B(+) UP
MASTER WINDOW SWITCH RIGHT FRONT DOWN
POWER WINDOW RIGHT REAR B(+) DOWN
NSGS8025 J988W-3

FUNCTION CIRCUIT
DRIVER POWER SEAT REAR UP
DRIVER POWER SEAT REAR DOWN
CAV
A
B
P11 14YL/WT
P13 14RD/WT
B A
BLACK
MOTOR
REAR VERTICAL
DRIVER SEAT
WINDOW MOTOR
DRIVER
RED
2 1
Q21 16WT
Q11 16LG
2
1
CAV
DRIVER WINDOW (DOWN)
DRIVER WINDOW (UP)
CIRCUIT FUNCTION
E40 RF3
CIRCUIT CAV
1
2
C23 12DG
Z1 12BK
CIRCUIT CAV
1
2
C23 12DG
Z1 12BK
1 2
BLACK
1 2
BLACK
RECLINER MOTOR
DRIVER SEAT
A B
BLACK
DRIVER SEAT RECLINER SWITCH UP
DRIVER SEAT RECLINER SWITCH DOWN
P41 14GY/WT
P43 14GY/LB
CIRCUIT CAV
A
B
FUNCTION
J988W-3 NSGS8026

(3.3L/3.8L)
F02
(3.3L/3.8L)
E78
7 1
8 14
BLACK
7 1
8 14
BLACK
K4 18BK/LB
K58 18BR/DB
K38 18GY
K2 18TN/BK
K1 18DG/RD
-
K44 18TN/YL
K7 18OR
K14 18LB/BR
K13 18YL/WT
K12 18TN/WT
K11 18WT/DB
K6 18VT/WT
A142 18DG/OR
14
13
12
11
10
9
8
7
6
5
4
3
2
1
CAV CIRCUIT
K4 18BK/LB
K58 18BR/DB
K38 18GY
K2 18TN/BK
K1 18DG/RD
-
K44 18TN/YL
K7 18OR
K14 18LB/BR
K13 18YL/WT
K12 18TN/WT
K11 18WT/DB
K6 18VT/WT
A142 18DG/OR
14
13
12
11
10
9
8
7
6
5
4
3
2
1
CAV CIRCUIT
(2.4L)
F09
(2.4L)
E69
7 1
8 14
BLACK
7 1
8 14
BLACK
K2 18TN/BK
K1 18DG/RD
A142 18DG/OR
C18 18DB
K6 18VT/WT
K52 18PK/BK
K70 18VT/RD
K4 18BK/LB
K14 18LB/BR
K13 18YL/WT
K12 18TN/WT
K11 18WT/DB
14
13
12
11
10
9
8
7
6
5
4
3
2
1
CAV
-
-
CIRCUIT
K2 18TN/BK
K1 18DG/RD
A142 18DG/OR
C18 18DB
K6 18VT/WT
K52 18PK/BK
K70 18VT/RD
K4 18BK/LB
K14 18LB/BR
K13 18YL/WT
K12 18TN/WT
K11 18WT/DB
14
13
12
11
10
9
8
7
6
5
4
3
2
1
CAV
-
-
CIRCUIT
BLACK
1 3
4 6
1
4 6
3
BLACK
(DIESEL) (DIESEL)
5
6
K153 18OR/DG 4
Z1 16BK
K57 20LG/OR
3
2
1 C137 20YL
1
2
3
4
6
5
E95 B107
K152 20WT/DG
K90 18TN K90 20OR/VT
K152 20WT/DG
K153 18OR/DG
Z12 14BK/TN
K57 20LG/OR
C137 20YL
NSGS8027 J988W-3

1 2
EGR SOLENOID CONTROL K35 20GY/YL 2
1 A142 18DG/OR
AUTO SHUTDOWN RELAY OUTPUT
(DIESEL)
EGR SOLENOID
EGR SOLENOID
2 1
GRAY
F87 18WT/BK
K35 18GY/YL
2
1
CAV
FUSED IGNITION SWITCH OUTPUT
EGR SOLENOID CONTROL
CIRCUIT FUNCTION
(2.4L MTX/3.3L/3.8L)
Z1 18BK
K126 20LG
Z1 18BK
K67 20BR/BK
K68 20LG/YL
K24 18GY/BK
K4 18BK/LB
Z12 18BK
K2 20TN/BK
C13 20DB/OR
C24 20DB/PK C24 20DB/PK
BLACK
CIRCUIT CAV
1
2
3
4
6
5
B106
(DIESEL)
E97
(DIESEL)
10
9
8
7
C13 20DB/OR
K2 20TN/BK
Z122 18BK 7
8
9
10
5
6
K68 18LG/YL 4
K67 18BR/BK
Z122 18BK
3
2
1 K126 18LG
CAV CIRCUIT
K24 20GY/BK
K4 20BK/LB
BLACK
1
6
5
10
5
10
1
6
6
1
10
5
LT. GRAY
K135 18WT/BK
K134 18LB/BK
CIRCUIT CAV
A142 18DG/OR 1
2
3
K35 20GY/YL
K51 20DB/YL
4 G7 18WT/OR
6
5
10
9
8
7 A142 18DG/OR
K140 18TN/WT
K156 18GY
- -
K156 20GY
K140 18TN/WT
A142 18DG/OR 7
8
9
10
(DIESEL)
E96
(DIESEL)
B108
5
6
G7 18WT/OR 4
K51 20DB/YL
K35 20GY/YL
3
2
1 A142 18DG/OR
CAV CIRCUIT
K134 20LB/BK
K135 20WT/BK
LT. GRAY
5
10
1
6
J988W-3 NSGS8028

1 2
- - 2
1 V20 18RD
BLACK
WIPER DE-ICER-C1
ELECTRIC
ELECTRIC
WIPER DE-ICER-C2
BLACK
WIPER DE-ICE SWITCHED GROUND
C66 18BK/WT 1
2 - -
2 1
SENSOR GROUND K4 20BK/LB 2
1 K2 20TN/BK
ENGINE COOLANT TEMPERATURE SENSOR SIGNAL
ENGINE COOLANT TEMPERATURE SENSOR SIGNAL G58 20BK/YL 3
ENGINE COOLANT
TEMPERATURE SENSOR
(DIESEL)
1
2
3
BLACK
(GAS)
TEMPERATURE SENSOR
ENGINE COOLANT
1 2
BLACK
K2 18TN/BK
K4 18BK/LB
2
1
CAV
SENSOR GROUND
CIRCUIT FUNCTION
PRESSURE SWITCH
ENGINE OIL
BLACK (2.0L)
1
GREEN
2
G6 16GY
2
1
CAV
-
CIRCUIT
-
FUNCTION
NSGS8029 J988W-3

SOLENOID
EVAP/PURGE
2 1
BLACK
K70 18VT/RD
K52 18PK/BK
2
1
CAV
EVAP/PURGE CURRENT SENSE
EVAP/PURGE SOLENOID CONTROL
CIRCUIT FUNCTION
TEMPERATURE SENSOR
EVAPORATOR
CIRCUIT FUNCTION
A/C SWITCH SENSE
SENSOR GROUND
CAV
1
2
C21 20DB/OR
C57 20DB/GY
1
2
BLACK
(3.3L/ETHANOL)
SENSOR
FLEXIBLE FUEL
FLEXIBLE FUEL SENSOR SIGNAL
SENSOR GROUND
8V SUPPLY
LT. GRAY
1 4
- - 4
K50 18YL/WT 3
FUNCTION
1
CAV
K7 18OR
CIRCUIT
2 K4 18BK/LB
(EXCEPT BUILT-UP-EXPORT)
DETECTION PUMP
EVAP LEAK
LEAK DETECTION PUMP SWITCH SENSE K107 18YL/BK** 4
F87 18WT/BK
K106 18WT/DG
K107 18DB/WT*
4
3
2
1
CAV
LEAK DETECTION PUMP SOLENOID CONTROL
LEAK DETECTION PUMP SWITCH SENSE
-
FUNCTION
-
CIRCUIT GRAY
LIGHT
1
1 3
ENGINE SPEED
SENSOR
(DIESEL)
ENGINE SPEED SENSOR SIGNAL K24 20GY/BK 3
- -
ENGINE SPEED RETURN K3 20BK/VT
2
1
* 3.3L/3.8L
** 2.4L
1
J988W-3 NSGS8030

GROUND Z1 16BK 3
FUSED B(+) F30 16RD
POWER OUTLET
FRONT CIGAR LIGHTER
2 1
FUSED PANEL LAMPS DIMMER SWITCH SIGNAL E2 20OR 2
1
BLOCK
FRONT BLOWER
MOTOR RESISTOR
BLACK
10
5
6
1
C4 16TN
C107 12TN/BK
C104 12RD/WT
C6 14LB
C5 16LG
10
9
8
7
6
5
4
3
2
1
CAV
LOW SPEED BLOWER MOTOR
-
-
-
-
-
CIRCUIT
-
-
-
-
-
FUNCTION
MOTOR
FRONT BLOWER
1 2
BLACK
C7 12BK/TN
C71 12DB
2
1
CAV
BLOWER MOTOR DRIVER
CIRCUIT FUNCTION
RED/BLUE
3
NSGS8031 J988W-3

A141 18DG/WT 1
2 Z1 18BK GROUND
(DIESEL)
FUEL HEATER
BLACK
2 1
MOTOR
FRONT WASHER
BLACK
A B
V10 20BR
F1 20DB
B
A
CAV
WASHER PUMP CONTROL SWITCH OUTPUT
FUNCTION CIRCUIT
CIRCUIT FUNCTION
FRONT READING LAMP FEED
FUSED B(+)
CAV
1
2
3
M13 20BK/YL
M20 20BR
F41 20PK/VT
BLACK
3 1
FRONT
READING LAMPS/
SWITCH
FRONT
READING LAMPS/
SWITCH
(OVERHEAD CONSOLE)
BLUE
PANEL LAMPS FEED
-
FRONT READING LAMP FEED
GROUND
FUSED (B+)
Z2 18BK/LG
F41 20PK/VT
- 5
4
3
CIRCUIT
M13 20BK/YL
E2 18OR
CAV
2
1
FUNCTION
COURTESY LAMP GROUND M20 20BR 6
1 3
6 4
J988W-3 NSGS8032

BLACK
2 1
FUEL INJECTOR
NO. 1
(2.0L/2.4L)
AUTO SHUTDOWN RELAY OUTPUT A142 18DG/OR 2
1 K11 18WT/DB
INJECTOR NO. 1 DRIVER
(3.3L/3.8L)
NO. 1
FUEL INJECTOR
1 2
BLACK
K11 18WT/DB
A142 18DG/OR
2
1
CAV
AUTOMATIC SHUTDOWN RELAY OUTPUT
CIRCUIT FUNCTION
K12 18TN/WT 1
2 A142 18DG/OR AUTO SHUTDOWN RELAY OUTPUT
(2.0L/2.4L)
NO. 2
FUEL INJECTOR
1 2
BLACK
(3.3L/3.8L)
NO. 2
FUEL INJECTOR
1 2
BLACK
K12 18TN/WT
A142 18DG/OR
2
1
CAV
CIRCUIT FUNCTION
K13 18YL/WT 1
(2.0L/2.4L)
NO. 3
FUEL INJECTOR
1 2
BLACK
NSGS8033 J988W-3

(3.3L/3.8L)
NO. 3
FUEL INJECTOR
1
BLACK
2
K13 18YL/WT
A142 18DG/OR
2
1
CAV
CIRCUIT FUNCTION
(3.3L/3.8L)
NO. 6
FUEL INJECTOR
1
BLACK
2
K58 18BR/DB
A142 18DG/OR
2
1
CAV
CIRCUIT FUNCTION
(3.3L/3.8L)
NO. 5
FUEL INJECTOR
1
BLACK
2
K38 18GY
A142 18DG/OR
2
1
CAV
CIRCUIT FUNCTION
(3.3L/3.8L)
NO. 4
FUEL INJECTOR
1
BLACK
2
K14 18LB/BR
A142 18DG/OR
2
1
CAV
CIRCUIT FUNCTION
K14 18LB/BR 1
(2.0L/2.4L)
NO. 4
FUEL INJECTOR
1 2
BLACK
J988W-3 NSGS8034

Z2 20BK
Z1 20BK
Z1 18BK**
GROUND
G200
14
7
8
1
8 14
1
BLACK
BLACK
7
BUS BAR
14
13
12
11
10
9
8
7
6
5
4
3
2
1
CAV CIRCUIT
Z1 20BK
Z1 18BK
Z2 20BK/LG
Z1 16BK
Z1 20BK
Z1 20BK
Z2 18BK/LG
Z2 20BK/LG
Z2 20BK/LG
Z2 20BK/LG
14
13
12
11
10
9
8
7
6
5
4
3
2
1
CAV
-
CIRCUIT
* GAS
BACK-UP LAMP FEED L1 20VT/BK
TANK MODULE
FUEL
GRAY
LIGHT
4 1
A141 16DG/WT*
G4 18DB
Z1 16BK
4
3
2
1
CAV
FUEL LEVEL SENSOR SIGNAL
GROUND
FUNCTION CIRCUIT
SHUT OFF FEED K153 18OR/DG
SLEEVE POSITION SENSOR (-)
K134 18LB/BK 1
2 K57 18LG/OR
3 K135 18WT/BK SLEEVE POSTION SENSOR (+)
6
K126 18LG SOLENOID CONTROL
SENSOR GROUND K4 20BK/LB
5
4
FUEL TEMPERATURE SENSOR SIGNAL K156 18GY 7
8 K140 18TN/WT
9 A142 18DG/OR
A142 18DG/OR 10
CONTROL SLEEVE POSTION SENSOR
(DIESEL)
MODULE
FUEL PUMP
** RHD
1
6 10
5
BLACK
NSGS8035 J988W-3

Z12 14BK/TN**
7
Z1 18BK
G300
Z1 20BK
*** LHD
** DIESEL
* GAS
8
1
14
7
8
1
14
7
BLACK
11
9
6
Z1 BUS BAR
14
13
12
10
8
7
5
4
3
2
1
CAV CIRCUIT
Z1 18BK 11
9
6
Z1 20BK
Z1 14BK
Z1 18BK
Z1 20BK
Z1 20BK
Z1 14BK
Z1 12BK*
Z1 18BK
Z1 20BK***
Z1 12BK
Z1 12BK
Z1 20BK
14
13
12
10
8
5
4
3
2
1
CAV
-
-
CIRCUIT
Z12 20BK/TN*
BUILT-UP-EXPORT
J988W-3 NSGS8036

(DIESEL)
(DIESEL)
G301
BLACK
Z12 18BK
8
1
14
7
BLACK
8
1
14
7
Z1 BUS BAR
14
13
12
11
10
9
8
7
6
5
4
3
2
1
CAV CIRCUIT
Z1 18BK
Z1 18BK
Z1 18BK
Z1 20BK
Z1 12BK
Z2 20BK/LG
Z2 20BK/LG
Z1 18BK
Z11 20BK/WT
14
13
12
11
10
9
8
7
6
5
4
3
2
1
CAV
-
CIRCUIT
Z2 18BK/LG
Z1 18BK
Z1 20BK
Z1 18BK
Z1 20BK
1
3
(GAS)
G301
BLACK
8
1
14
7
BLACK
8
1
14
7
Z1 BUS BAR
14
13
12
11
10
9
8
7
6
5
4
3
2
1
CAV CIRCUIT
Z1 20BK
Z1 18BK
Z1 18BK
Z1 20BK
Z1 20BK**
Z2 18BK/LG
Z2 20BK/LG
Z2 20BK/LG
Z1 18BK
14
13
12
11
10
9
8
7
6
5
4
3
2
1
CAV
-
-
CIRCUIT
Z1 20BK
Z1 18BK
Z1 18BK
BUILT-UP-EXPORT
** EXCEPT BUILT-UP-EXPORT/PLYMOUTH, DODGE
* EXCEPT BUILT-UP-EXPORT/CHRYSLER
Z1 20BK*
7
Z1 20BK*
7
NSGS8037 J988W-3

8
1
14
7
BLACK
8
1
14
7
BLACK
Z1 BUS BAR
14
13
12
11
10
9
8
7
6
5
4
3
2
1
CAV CIRCUIT
Z1 20BK
Z2 20BK/LG
Z1 20BK
Z1 20BK
Z1 18BK
Z1 12BK
Z1 20BK
Z1 20BK
Z1 12BK
14
13
12
11
10
9
8
7
6
5
4
3
2
1
CAV
-
-
-
-
-
CIRCUIT
* REAR A/C-HEATER
BLACK
8
1
14
7
BLACK
8
1
14
7
Z1 BUS BAR
14
13
12
11
10
9
8
7
6
5
4
3
2
1
CAV CIRCUIT
Z1 18BK
Z1 18BK*
Z1 16BK
Z1 12BK
Z1 20BK
Z1 18BK
Z1 14BK
Z1 20BK
14
13
12
11
10
9
8
7
6
5
4
3
2
1
CAV
-
-
-
-
-
-
CIRCUIT
G302
G400
GENERATOR
2 3
1
BLACK
K20 18DG
A142 18DG/OR
3
2
1
CAV
GENERATOR FIELD DRIVER
ASD RELAY OUTPUT
-
FUNCTION
-
CIRCUIT
(GAS)
J988W-3 NSGS8038

4
1
GLOW PLUG
RELAY
(DIESEL)
FUSED B(+)
A54 10RD 1
2 K152 18WT/DG GLOW PLUG RELAY CONTROL SENSE
2 3
3
4 K154 10GY
A142 18DG/OR AUTO SHUTDOWN RELAY OUTPUT
GLOW PLUG RELAY CONTROL
BLACK
GLOVE BOX LAMP
BLUE
2 1
M20 20BR
F41 20PK/VT
2
1
CAV
FUSED B(+)
FUNCTION CIRCUIT
HEADLAMP LEVELING SIGNAL L13 20BR/YL*
GROUND
L44 20VT/RD*
Z1 20BK*
HEADLAMP SWITCH - C1
* BUILT-UP-EXPORT
NATURAL
13
6
7
1
5
E92 22OR/BK
M113 20LB/PK
M13 20BK/YL
M111 22BR/WT
Z1 20BK
E17 20YL/BK
E17 20YL/BK
M32 22BK/LB
M112 22BR/LG
13
12
11
10
9
8
7
6
4
3
2
1
CAV
DIMMER SWITCH SIGNAL
READING LAMP FEED
GROUND
COURTESY LAMP SWITCH SENSE
-
-
FUNCTION
-
-
CIRCUIT
3 4
2 1
BLACK
4
2
3
1
BLACK
A2 12PK/BK
Z1 14BK
4
3
2
1
CAV
-
CIRCUIT
A2 12PK/BK
Z1 14BK
4
3
2
1
CAV CIRCUIT
HS6D S02 F35 14RD F35 14RD
(HEATED SEAT)
F35 14RD F35 14RD
S02 HS6P
CIRCUIT CAV
1
2
3
4
CIRCUIT
-
CAV
1
2
3
4
BLACK
1
3
2
4
BLACK
1 2
4 3
-
- -
- -
-
Z1 20BK
FUSED RIGHT LOW BEAM OUTPUT
NSGS8039 J988W-3

SWITCH - C2
HEADLAMP
GROUND Z39 18BK
L36 20LG REAR FOG LAMP
8
4
5
BLACK
1
L308 20LG/WT
L77 18BR/YL
L307 20LG/OR
Z1 18BK
E2 20OR
8
7
6
5
4
3
2
1
CAV
PARK LAMP SWITCH SENSE
FUSED LEFT INBOARD TAIL LAMP
HEADLAMP SWITCH SENSE
GROUND
PANEL LAMPS FEED
-
FUNCTION
-
CIRCUIT
A B
WASHER RELAY OUTPUT V53 18RD/YL B
A Z1 18BK
GROUND
(BUILT-UP-EXPORT)
WASHER
HEADLAMP
HIGH NOTE HORN
B
BLACK
A
Z1 18BK
X2 18DG/RD
B
A
CAV
GROUND
HORN RELAY OUTPUT
CIRCUIT FUNCTION
5 L39 18LB* FOG LAMP SWITCH OUTPUT
7 L110 22BK/YL* SENSOR SIGNAL
J988W-3 NSGS8040

SWITCH
HOOD AJAR
NATURAL
2
1
Z1 18BK
G70 18BR/TN
2
1
CAV
GROUND
HOOD AJAR SWITCH SENSE
CIRCUIT FUNCTION
SWITCH
HORN/SPEED CONTROL
4
NATURAL
1
V37 20RD/LG
Z2 20BK/LG
X3 20BK/RD
4
3
2
1
CAV
GROUND
HORN RELAY DRIVER
-
CIRCUIT
-
FUNCTION
FUNCTION CIRCUIT
IDLE AIR CONTROL MOTOR NO.4 DRIVER
CAV
1
2
3
4
K59 18VT/BK
K40 18BR/WT
K60 18YL/BK
K39 18GY/RD
BLACK
4 1
IDLE AIR
CONTROL
MOTOR
(2.0L/2.4L)
IGNITION COIL PACK
3 1
BLACK
K19 18GY/RD
A142 18DG/OR
K17 18DB/TN
3
2
1
CAV
IGNITION COIL NO. 1 DRIVER
ASD RELAY OUTPUT
CIRCUIT FUNCTION
(3.3L/3.8L)
IGNITION COIL PACK
BLACK
3 4
2 1
K17 18DB/TN
A142 18DG/OR
K19 18GY/RD
K18 18RD/YL
4
3
2
1
CAV
IGNITION COIL DRIVER NO. 2, 5
ASD RELAY OUTPUT
CIRCUIT FUNCTION
NSGS8041 J988W-3

IGNITION SWITCH - C1
BLACK
10 6
5 1
A41 12YL
A21 12DB
A31 12BK/WT
A1 12RD
A22 12BK/OR
A2 12PK/BK
G9 20GY/BK
Z1 20BK
10
9
8
7
6
5
4
3
2
1
CAV
IGNITION SWITCH OUTPUT (START)
IGNITION SWITCH OUTPUT (ST-RUN)
IGNITION SWITCH OUTPUT (RUN-ACC)
FUSED B(+)
IGNITION SWITCH OUTPUT (RUN)
FUSED B(+)
GROUND
-
-
CIRCUIT
-
-
FUNCTION
2 1
GREEN
Z1 20BK
G26 20LB
2
1
CAV
GROUND
CIRCUIT FUNCTION
1 2
BLACK
A81 20DG/RD
M1 20PK
2
1
CAV
IGNITION SWITCH OUTPUT (OFF/RUN/START)
FUSED B(+)
CIRCUIT FUNCTION
INSTRUMENT CLUSTER
RED
7
1
13
6
11
Z1 20BK
F11 20RD/WT
D1 20VT/BR
D2 20WT/BK
Z2 20BK/LG
E2 20OR
M1 20PK
13
12
10
9
8
7
6
5
4
3
2
1
CAV
GROUND
FUSED IGNITION (ST-RUN-OFF)
CCD BUS (+)
CCD BUS (-)
GROUND
PANEL LAMPS FEED
FUSED B(+)
-
-
-
-
-
-
CIRCUIT
-
-
-
-
-
-
FUNCTION
J988W-3 NSGS8042

(2.0L)
PRESSURE SENSOR
MANIFOLD ABSOLUTE
TEMPERATURE/
INTAKE AIR
MAP SENSOR SIGNAL K1 18DG/RD D
C K6 18VT/WT 5 VOLT SUPPLY
SENSOR GROUND
K4 18BK/LB A
B K21 18BK/RD INTAKE AIR TEMPERATURE SIGNAL
A D
(2.4L)
TEMPERATURE SENSOR
INTAKE AIR
1 2
DARK
K21 18BK/RD
K4 18BK/LB
2
1
CAV
INTAKE AIR TEMPERATURE SIGNAL
SENSOR GROUND
CIRCUIT FUNCTION
6 1
L16 J03A
- -
6 1
BLACK
P98 20WT/RD
G78 18TN/BK
V23 18BR/PK
V13 18BR/LG
C15 12BK/WT
6
5
4
3
2
1
CAV CIRCUIT
P98 20WT/RD
G78 18TN/BK
V23 18BR/PK
V13 18BR/LG
C15 12BK/WT
6
5
4
3
2
1
CAV CIRCUIT
L15 J02A
1 6
6 1
BLACK
L77 20BR/LB
F136 20VT/WT
F133 20BR/RD
M11 20PK/LB
L50 20WT/TN
Z1 12BK
6
5
4
3
2
1
CAV CIRCUIT
L77 20BR/LB
F136 20VT/WT
F133 20BR/RD
M11 20PK/LB
L50 20WT/TN
Z1 12BK
6
5
4
3
2
1
CAV CIRCUIT
BLACK
GRAY
NSGS8043 J988W-3

JUNCTION BLOCK - C1
A2 12PK/BK FUSED B(+)
F87 18WT/BK FUSED IGNITION SWITCH OUTPUT
- -
V23 18BR/PK FUSED IGNITION SWITCH OUTPUT
A4 12BK/RD FUSED B(+)
L78 20DG/YL FUSED B(+)
FUSED B(+) L78 20DG/YL
- -
- -
- -
- -
- -
- -
PANEL LAMPS FEED E2 20OR
F133 20BR/YL LOCK RELAY OUTPUT
LOCK RELAY OUTPUT F133 20BR/YL
F133 20BR LOCK RELAY OUTPUT
LOCK RELAY OUTPUT F133 20BR
FOG LAMP SWITCH OUTPUT L39 18LB*
FOG LAMP SWITCH OUTPUT L39 18LB*
L77 20BR/LB
L77 20BR/LB
FOG LAMP RELAY OUTPUT L39 18LB
FUSED LEFT LOW BEAM OUTPUT
FUSED LEFT LOW BEAM OUTPUT L43 18VT*
L43 18VT*
FUSED IGNITION SWITCH OUTPUT V23 18BR/PK
L94 20OR/WT LOW BEAM RELAY CONTROL
LOCK RELAY OUTPUT F133 20BR/RD
FUSED LEFT INBOARD TAIL LAMP L77 18BR/YL
C15 12BK/WT
A2 12PK/BK
REAR DEFOGGER RELAY OUTPUT
FUSED B(+)
E2 20OR**
L7 12BK/YL
F11 20RD/WT
X1 16DG/RD
PANEL LAMPS FEED
PARK LAMP RELAY OUTPUT
FUSED IGNITION SWITCH OUTPUT (ST-RUN-OFF)
F131 20BK/PK
M1 20PK
M1 20PK
F136 20VT/WT
F136 20VT/WT
F136 20VT/YL
F136 20VT/YL
DRIVER UNLOCK RELAY OUTPUT
FUSED B (+)
FUSED B (+)
UNLOCK RELAY OUTPUT
UNLOCK RELAY OUTPUT
UNLOCK RELAY OUTPUT
UNLOCK RELAY OUTPUT
36
29
22
18
14
7
30
23
19
15
8
1
GRAY
36
35
34
33
32
31
30
29
28
27
26
25
24
23
22
21
20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
CAV CIRCUIT FUNCTION
F39 18PK/LG FUSED B(+)
FUSED B(+)
DIESEL
EATX
MEMORY SEAT
BUILT-UP-EXPORT
* CHRYSLER
** REAR A/C-HEATER
F39 18PK/LG
FUSED LEFT INBOARD TAIL LAMP L77 20BR/YL
5 L77 20BR/YL FUSED LEFT INBOARD TAIL LAMP
F87 18WT/BK FUSED IGNITION SWITCH OUTPUT
V53 18RD/YL WASHER RELAY OUTPUT
P174 20YL/RD POWER MIRROR UNFOLD RELAY
E2 20OR PANEL LAMPS FEED
J988W-3 NSGS8044

BUILT-UP-EXPORT
RIGHT TURN SIGNAL L62 18BR/RD
36
POWER MIRROR FOLD RELAY P171 20VT/WT
LEFT TURN SIGNAL L63 18DG/RD
RED BRAKE WARNING LAMP DRIVER G9 20GY/BK
FUSED IGNITION SWITCH OUTPUT (RUN-ACC)
JUNCTION BLOCK - C2
- -
FUSED B(+) F20 18WT
F20 20WT FUSED B(+)
L62 18BR/RD RIGHT TURN SIGNAL
L9 18BK/WT FUSED FLASHER FEED
LEFT TURN SIGNAL
- -
- -
- -
- -
- -
DOME LAMP FEED M113 20LB/PK
FUSED IGNITION SWITCH OUTPUT F55 12TN/DG
L61 18LG LEFT TURN SIGNAL
F1 20DB
Z1 14BK GROUND
36
29
22
18
14
7
30
23
19
15
8
1
GRAY
L60 18TN
A22 12BK/OR
M11 20PK/LB
M11 20PK/LB
L63 18DG/RD
F21 16TN
L97 18PK/DB
V10 20BR
C40 12BR/WT*
F45 20YL/RD
F55 12TN/DG
F1 20DB
F41 20PK/VT
F41 20PK/VT
F20 20WT
F1 20DB
M11 20PK/LB
X4 20GY/OR
G9 20GY/BK
35
34
33
32
31
30
29
28
27
26
25
24
23
22
21
20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
CAV
RIGHT TURN SIGNAL
PARK LAMP RELAY CONTROL
5-VOLT SUPPLY
FUSED B(+) ENGINE STARTER MOTOR RELAY
FUSED B(+)
FUSED B(+)
FUSED B(+)
HORN RELAY CONTROL
-
CIRCUIT
-
FUNCTION
F133 20BR/YL** LOCK RELAY OUTPUT
F133 20BR/YL** LOCK RELAY OUTPUT
** GAS, EXCEPT BUILT-UP-EXPORT
* REAR A/C
NSGS8045 J988W-3

L91 20DB/PK
FUSED IGNITION SWITCH OUTPUT X12 20RD/WT
FUSED B(+) F41 20PK/VT**
POWER MIRROR FOLD
POWER MIRROR FOLD
P160 20LB**
P160 20LB**
JUNCTION BLOCK - C3
- -
- -
-
RIGHT TURN SWITCH SENSE L302 22LB/YL
LEFT TURN SIGNAL L63 18DG/RD
L62 18BR/RD RIGHT TURN SIGNAL
L305 22LB/WT LEFT TURN SWITCH SENSE
- -
- -
- -
- -
- -
- -
- -
NAME BRAND SPEAKER RELAY DRIVER X60 20RD/DG
RED BRAKE WARNING LAMP DRIVER G9 20GY/BK*
REAR WASHER MOTOR CONTROL V20 18RD
M11 20PK/LB
X12 18RD/WT
M112 22BR/LG
V10 20BR
G9 20GY/BK
G9 20GY/BK
F41 20PK/VT
F41 20PK/VT
FUSED B (+)
FUSED B(+)
L93 22PK
L91 22DB/PK
M113 20LB/PK
A31 12BK/WT
M111 22BR/WT
HIGH BEAM RELAY CONTROL
READING LAMP FEED
IGNITION SWITCH OUTPUT (RUN-ACC)
SWITCHED COURTESY LAMP RELAY CONTROL
36
23
22
15
14
1
30
29
19
18
8
7
GRAY
F1 20DB
A22 12BK/OR
36
35
34
33
32
31
30
29
28
27
26
25
24
23
22
21
20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
CAV
-
-
CIRCUIT
-
-
FUNCTION
RHD
GAS
* LHD
** BUILT-UP-EXPORT
L63 18DG/RD LEFT TURN SIGNAL
G9 20GY/BK RED BRAKE WARNING LAMP DRIVER
COMBINATION FLASHER SWITCHES GROUND
COMBINATION FLASHER SWITCHES GROUND
J988W-3 NSGS8046

GROUND Z1 20BK
FUSED IGNITION SWITCH OUTPUT F87 20WT/BK
POWER MIRROR UNFOLD
POWER MIRROR UNFOLD
P159 20DG
P159 20DG
FUSED IGNITION SWITCH OUTPUT (ST-RUN-OFF) F11 20RD/WT**
PANEL LAMPS FEED E2 20OR*
JUNCTION BLOCK - C4
GROUND Z1 20BK
A41 12YL IGNITION SWITCH OUTPUT (START)
PANEL LAMPS FEED
- -
- -
- -
- -
- -
- -
- -
- -
- -
- -
- -
Z1 20BK
Z1 18BK
GROUND
GROUND
21
GROUND Z1 20BK*
35
24
12
M1 20PK
M1 20PK
FUSED B (+)
FUSED B (+)
E2 18OR
E2 20OR
PANEL LAMPS FEED
PANEL LAMPS FEED
Z2 20BK/LG
FUSED B (+) M1 20PK
Z2 20BK/LG
GROUND
GROUND
- -
FUNCTION
1
CAV
4
3
5
6
2
CIRCUIT
7
9
8
11
10
13
14
15
16
17
18
19
20
22
23
25
26
28
29
31
30
32
27
34
36
33
36
29
22
18
14
7
30
23
19
15
8
1
GRAY
Z1 18BK
Z1 20BK
A21 12DB
C14 22WT/RD
C16 20LB/YL
C16 20LB/YL
Z1 20BK
Z1 20BK
Z1 20BK
E2 20OR
M1 20PK
M1 20PK
M1 20PK
E2 20OR
E2 20OR
F11 20RD/WT
E2 20OR
E2 20OR
A2 12PK/BK
A81 20DG/RD
V23 18BR/PK
V23 18BR/PK
GROUND
GROUND
IGNITION SWITCH OUTPUT (ST-RUN)
REAR DEFOGGER RELAY CONTROL
GROUND
GROUND
GROUND
PANEL LAMPS FEED
FUSED B (+)
FUSED B (+)
FUSED B (+)
PANEL LAMPS FEED
FUSED IGNITION SWITCH OUTPUT (ST-RUN-OFF)
PANEL LAMPS FEED
PANEL LAMPS FEED
FUSED B(+)
IGNITION SWITCH OUTPUT (ST-RUN-OFF)
BUILT-UP-EXPORT
REAR A/C
GAS, BUILT-UP-EXPORT
* GAS
** RHD
Z1 20BK GROUND
NSGS8047 J988W-3

LAMP
KEY-IN HALO
WHITE
1 2
1
M11 20PK/LB
Z1 20BK
2
CAV
COURTESY LAMP SWITCH OUTPUT
GROUND
CIRCUIT FUNCTION
(PREMIUM)
SPEAKER
LEFT DOOR
LEFT INSTRUMENT PANEL SPEAKER (-)
X55 20BR/RD LEFT FRONT SPEAKER (-)
RADIO CHOKE OUTPUT X13 16RD/DG
6
5
3
6 4
1
BLACK
X156 20VT/WT*
X53 20DG
X15 16BK/DG
X154 20WT/VT*
4
3
2
1
CAV
LEFT FRONT SPEAKER (+)
AMPLIFIED SPEAKER GROUND
LEFT INSTRUMENT PANEL SPEAKER (+)
FUNCTION CIRCUIT
RELAY
LEFT COMBINATION
4
2
3
5
1
BLACK
GROUND
3
2
L615 18OR
L50 18WT/TN
L50 18WT/TN
Z1 18BK
Z1 18BK
L63 18DG/RD
5
4
1
CAV
LEFT COMBINATION RELAY OUTPUT
LEFT TURN SIGNAL
-
CIRCUIT
-
FUNCTION
(2.0L/2.4L/3.8L)
KNOCK SENSOR
2 1
GRAY
K4 18BK/LB
K42 18DB/LG
2
1
CAV
SENSOR GROUND
KNOCK SENSOR SIGNAL
CIRCUIT FUNCTION
SWITCH
KEY-IN
1 2
GREEN
Z1 20BK
G26 20LB
2
1
CAV
GROUND
CIRCUIT FUNCTION
(TRAILER TOW)
X153 20WT/BR** LEFT INSTRUMENT PANEL SPEAKER (+)
X155 20BR/WT** LEFT INSTRUMENT PANEL SPEAKER (-)
** LHD
* RHD
J988W-3 NSGS8048

PANEL SPEAKER
LEFT FRONT
3
4
X154 20WT/VT LEFT INSTRUMENT PANEL SPEAKER (+)
BLACK
4 1
-
X156 20VT/WT
2
1
CAV
-
LEFT INSTRUMENT PANEL SPEAKER (-)
CIRCUIT FUNCTION
(PREMIUM)
SIGNAL LAMP
PARK/TURN
LEFT FRONT
3 1
BLACK
Z1 18BK
L77 20BR/YL
L61 18LG
3
2
1
CAV
GROUND
LEFT TURN SIGNAL
CIRCUIT FUNCTION
LEFT FRONT
SPEAKER
(BASE)
LEFT TURN SIGNAL L61 18LG 3
1 3
BLACK
GROUND Z1 18BK 2
1 L77 20BR/YL
(BUILT-UP-EXPORT)
TURN SIGNAL LAMP
LEFT FRONT PARK/
1 4
BLACK
FUNCTION CIRCUIT
-
LEFT FRONT SPEAKER (-)
CAV
1
2
-
X55 20BR/RD
LEFT FRONT SPEAKER (+)
-
X53 20DG
- 4
3
- -
FOG LAMP
LEFT
GRAY*
1
PURPLE**
2
2
1
BLACK
2
1
LEFT
FOG LAMP
(BUILT-UP-EXPORT)
1 2
Z39 20BK FOG LAMP SWITCHED GROUND
L39 18LB** FOG LAMP RELAY OUTPUT
L39 18VT/RD* FOG LAMP RELAY OUTPUT
Z39 20BK FOG LAMP SWITCHED GROUND
F39 18PK/LG FUSED PARK LAMP RELAY OUTPUT
X153 20WT/BR LEFT INSTRUMENT PANEL SPEAKER (+)
X155 20BR/WT LEFT INSTRUMENT PANEL SPEAKER (-)
** CHRYSLER
* DODGE/PLYMOUTH RHD
LHD
NSGS8049 J988W-3

LEFT HEADLAMP
2
1 3
BLACK
L33 20RD
Z1 20BK
L43 18VT
3
2
1
CAV
FUSED LEFT HIGH BEAM OUTPUT
GROUND
CIRCUIT FUNCTION
LEFT HEADLAMP
LEVELING MOTOR
(BUILT-UP-EXPORT)
GROUND
Z1 20BK 1
2 L13 20BR/YL HEADLAMP ADJUST SIGNAL
1 3
BLACK
3 L44 20VT/RD FUSED RIGHT LOW BEAM OUTPUT
3
LEFT HEADLAMP
(BUILT-UP-EXPORT)
FUSED LEFT HIGH BEAM OUTPUT
L33 20RD 1
2 L43 18VT FUSED LEFT LOW BEAM OUTPUT
2
1
BLACK
3 Z1 20BK GROUND
SPEED SENSOR
LEFT FRONT WHEEL
B9 18RD
B8 18RD/DB
2
1
CAV
LEFT FRONT WHEEL SPEED SENSOR (+)
LEFT FRONT WHEEL SPEED SENSOR (-)
CIRCUIT FUNCTION
(EXCEPT-BUILT-UP-EXPORT)
HEADLAMP (CHRYSLER)
LEFT HIGH
FUNCTION
B
A
CAV
Z1 20BK
L33 20RD
CIRCUIT
GROUND
FUSED LEFT HIGH BEAM OUTPUT B A
1 2
BLACK
J988W-3 NSGS8050

HEADLAMP (CHRYSLER)
LEFT LOW
B A
FUNCTION
A
CAV
L43 18VT
CIRCUIT
B Z1 20BK GROUND
FLOOD LAMP
LEFT LIFTGATE
2
1
BLACK
1
Z1 20BK
M11 20PK/LB
M11 20PK/LB
2
CAV
GROUND
CIRCUIT FUNCTION
LAMP ASSEMBLY
LEFT REAR
3
6
1
4
BLACK
Z1 20BK
L50 18WT/TN
L77 20BR/YL
L1 20VT/BK
L63 18DG/RD
6
5
4
3
2
1
CAV
GROUND
BACK-UP SWITCH OUTPUT
LEFT TURN SIGNAL
-
CIRCUIT
-
FUNCTION
FUNCTION CIRCUIT
LEFT TURN SIGNAL
BACK-UP SWITCH OUTPUT
GROUND
CAV
1
2
3
4
5
6
L63 18DG/RD
L1 20VT/BK
L77 20BR/LB
L50 18WT/TN
Z1 20BK
BLACK
4
1
6
3
LEFT REAR
LAMP ASSEMBLY
(BUILT-UP-EXPORT)
L36 20LG REAR FOG LAMP SWITCH OUTPUT
SWITCH
DOOR AJAR
LEFT REAR
2
1
NATURAL*
G77 18TN/OR
Z1 18BK
3
2
1
CAV
LEFT REAR DOOR AJAR SWITCH SENSE
GROUND
-
CIRCUIT
-
FUNCTION
READING LAMP
LEFT MID
1 3
GRAY
F41 20PK/VT
M20 20BR
M113 20LB/PK
3
2
1
CAV
FUSED B (+)
READING LAMP FEED
CIRCUIT FUNCTION
BLACK
* DIESEL
NSGS8051 J988W-3

PILLAR SPEAKER
LEFT REAR
BLACK
2 1
X151 20BR/YL
X157 20BR/LB
2
1
CAV
LEFT REAR PILLAR (+)
LEFT REAR PILLAR (-)
CIRCUIT FUNCTION
(PREMIUM)
(LHD)
VENT MOTOR
LEFT REAR
3 1
NATURAL
Q23 18RD/WT
Q13 18DB
3
2
1
CAV
LEFT REAR VENT MOTOR (OPEN)
LEFT REAR VENT MOTOR (CLOSE)
CIRCUIT FUNCTION
SPEAKER
LEFT REAR
6
3
6
5
4
1
BLACK
3
2
X57 20BR/LB
X13 16RD/DG*
X157 20BR/LB*
X51 20BR/YL
X15 16BK/DG*
X151 20BR/YL*
4
1
CAV
LEFT REAR SPEAKER (-)
RADIO CHOKE OUTPUT
LEFT REAR SPEAKER (+)
AMPLIFIER SPEAKER GROUND
CIRCUIT FUNCTION
CONTACTS
SLIDING DOOR
LEFT REAR
3 1
BLACK
F136 20VT/WT
F133 20BR/YL
3
2
1
CAV
FUSED DOOR UNLOCK RELAY OUTPUT
FUSED DOOR LOCK RELAY OUTPUT
-
CIRCUIT
-
FUNCTION
READING LAMP
LEFT REAR
3 1
GRAY
F41 20PK/VT
M20 20BR
M113 20LB/PK
3
2
1
CAV
FUSED B (+)
CIRCUIT FUNCTION
* PREMIUM
- -
J988W-3 NSGS8052

MIRROR LAMPS
LEFT VISOR/VANITY
A B
BLACK
F41 20PK/VT
M20 20BR
B
A
CAV
FUSED B (+)
FUNCTION CIRCUIT
SIGNAL RELAY
LEFT STOP/TURN
1
4
2
3
5
BLACK
LEFT COMBINATION RELAY OUTPUT
LEFT STOP/TURN SIGNAL OUTPUT
1
4
2
L615 18OR
L63 18DG/RD
L63 18DG/RD
L73 18YL
Z1 18BK
Z1 18BK
L50 18WT/TN
L50 18WT/TN
5
3
CAV
LEFT REAR TURN SIGNAL
GROUND
CIRCUIT FUNCTION
GRAY
GROUND Z1 18BK 2
1 L63 18DG/RD
LEFT REPEATER LAMP SIGNAL
1 2
SENSOR
WHEEL SPEED
LEFT REAR
GRAY
2 1
B4 18LG
B3 18LG/DB
2
1
CAV
LEFT REAR WHEEL SPEED SENSOR (+)
LEFT REAR WHEEL SPEED SENSOR (-)
FUNCTION CIRCUIT
LEFT REAR VENT MOTOR (OPEN) Q24 18DG 3
3 1
NATURAL
LEFT REAR
VENT MOTOR
(RHD)
LEFT REAR VENT MOTOR (CLOSE) Q14 18GY 2
1 -
-
LEFT REPEATER
LAMP
(BUILT-UP-EXPORT)
(TRAILER TOW)
NSGS8053 J988W-3

LICENSE LAMP
1 3
GRAY
L77 20BR/LB
Z1 20BK
3
2
1
CAV
GROUND
-
CIRCUIT
-
FUNCTION
LOW NOTE HORN
A B
BLACK
Z1 18BK
X2 18DG/RD
B
A
CAV
HORN RELAY OUTPUT
GROUND
CIRCUIT FUNCTION
FLUID SWITCH
LOW WASHER
A B
BLACK
G29 20BK/TN
Z1 20BK
B
A
CAV
WASHER FLUID SWITCH SENSE
GROUND
CIRCUIT FUNCTION
LOCK MOTOR
LIFTGATE
1 3
BLACK
F136 20VT/WT
F133 20BR/RD
3
2
1
CAV
LOCK RELAY OUTPUT
UNLOCK RELAY OUTPUT
-
CIRCUIT
-
FUNCTION
DISARM SWITCH
LIFTGATE ARM/
2 1
GRAY
P98 20WT/RD
Z2 20BK/LG
2
1
CAV
LIFTGATE LOCK/UNLOCK MUX
GROUND
CIRCUIT FUNCTION
AJAR SWITCH
LIFTGATE
3 1
BLACK
G78 18TN/BK
Z1 20BK
3
2
1
CAV
LIFTGATE AJAR SWITCH SENSE
GROUND
-
CIRCUIT
-
FUNCTION
COOLANT LEVEL SWITCH SENSE
G18 20BK/PK 1
2 Z1 20BK GROUND
(DIESEL)
LEVEL SWITCH
LOW COOLANT
BLACK
2 1
J988W-3 NSGS8054

(2.4L/3.3L/3.8L)
PRESSURE SENSOR
MANIFOLD ABSOLUTE
C
A B
BLACK
K1 18DG/RD
K6 18VT/WT
K4 18BK/LB
C
B
A
CAV
MAP SENSOR SIGNAL
5 VOLT SUPPLY
SENSOR GROUND
CIRCUIT FUNCTION
6
1
10
5
GREEN
2
P21 22RD/LG
P13 22RD/WT
P11 22YL/WT
P19 22YL/LG
P15 22YL/LB
P9 20RD
P48 22GY/WT
P17 22RD/LB
P40 22GY/LB
Z1 20BK
10
9
8
7
6
5
4
3
1
CAV
SEAT FRONT VERTICAL (DOWN)
SEAT REAR VERTICAL (DOWN)
SEAT REAR VERTICAL (UP)
SEAT FRONT VERTICAL (UP)
SEAT HORIZONTAL (FORWARD)
FUSED B (+)
SEAT RECLINER (REARWARD)
SEAT HORIZONTAL (REARWARD)
(SEAT BACK UP)
RECLINER SWITCH TO MEMORY MODULE
GROUND
CIRCUIT FUNCTION
MEMORY POWER
SEAT SWITCH
HORIZONTAL MOTOR
MEMORY SEAT
A B
BLACK
P117 14RD/LB
P115 14YL/LB
B
A
CAV
CIRCUIT FUNCTION
POSITION SENSOR
FRONT VERTICAL
MEMORY SEAT
A C
BLACK
P28 20BR/RD
P26 22BR
P29 20BR/WT
C
B
A
CAV
SEAT POSITION SENSE COMMON
SEAT FRONT VERTICAL POSITION SENSE
5 VOLT SUPPLY
CIRCUIT FUNCTION
VERTICAL MOTOR
MEMORY SEAT FRONT
A B
BLACK
P119 14YL/LG
P121 14RD/LG
B
A
CAV
CIRCUIT FUNCTION
NSGS8055 J988W-3

POSITION SENSOR
RECLINER
MEMORY SEAT
C A
BLACK
P29 20BR/WT
P47 22LB
P28 20BR/RD
C
B
A
CAV
5 VOLT SUPPLY
SEAT RECLINER POSITION SENSE
CIRCUIT FUNCTION
RECLINER MOTOR
MEMORY SEAT
BLACK
B A P41 14GY/WT
P43 14GY/LB
B
A
CAV
SEAT RECLINER (FORWARD)
CIRCUIT FUNCTION
POSITION SENSOR
REAR VERTICAL
MEMORY SEAT
C A
BLACK
P29 20BR/WT
P27 22LB/RD
P28 20BR/RD
C
B
A
CAV
5 VOLT SUPPLY
SEAT REAR VERTICAL POSITION SENSE
CIRCUIT FUNCTION
VERTICAL MOTOR
MEMORY SEAT REAR
B A
BLACK
P113 14RD/WT
P111 14YL/WT
B
A
CAV
CIRCUIT FUNCTION
HORIZONTAL
POSITION SENSOR
MEMORY SEAT
A C
BLACK
P29 20BR/WT
P25 22VT/RD
P28 20BR/RD
C
B
A
CAV
5 VOLT SUPPLY
SEAT HORIZONTAL POSITION SENSE
CIRCUIT FUNCTION
J988W-3 NSGS8056

MODULE - C2
MEMORY SEAT/MIRROR
6
1
10
BLACK
5
P121 14RD/LG
P41 14GY/WT
F35 14RD
Z1 14BK
P113 14RD/WT
P119 14YL/LG
P43 14GY/LB
P111 14YL/WT
P115 14YL/LB
P117 14RD/LB
10
9
8
7
6
5
4
3
2
1
CAV
FUSED B (+)
GROUND
CIRCUIT FUNCTION
MODULE - C1
MEMORY SEAT/MIRROR
25
12
13
BLACK
1
P74 20DB
P72 20YL/BK
P70 20WT
P24 20PK/WT
P23 20PK/RD
G96 20LG/RD
M1 20PK
P68 20DG/RD
P67 20YL/RD
P66 20WT/BK
P75 20DB/WT
P71 20YL
P73 20YL/PK
P22 20PK/BK
P65 20DB/YL
P64 20YL/OR
P69 20WT/RD
25
24
23
22
21
20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
CAV
RIGHT MIRROR (HORIZONTAL)
RIGHT MIRROR (VERTICAL)
RIGHT MIRROR (COMMON)
MEMORY NO. 2
MEMORY NO. 1
RKE INTERFACE
FUSED B (+)
RIGHT MIRROR POSITION (HORIZONTAL)
RIGHT MIRROR POSITION (VERTICAL)
RIGHT MIRROR POSITION (GROUND)
LEFT MIRROR (HORIZONTAL)
LEFT MIRROR (VERTICAL)
LEFT MIRROR (COMMON)
MEMORY SET
LEFT MIRROR POSITION (HORIZONTAL)
LEFT MIRROR POSITION (VERTICAL)
LEFT MIRROR POSITION (GROUND)
-
-
-
-
-
-
-
-
CIRCUIT
-
-
-
-
-
-
-
-
FUNCTION
NSGS8057 J988W-3

(LHD)
MESSAGE CENTER
* DIESEL
WAIT-TO START WARNING LAMP DRIVER G85 20OR/BK * 7
BLUE
7
1
13
6
G69 22BK/OR
M1 20PK
R41 18BK/TN
V23 18BR/PK
G9 20GY/BK
G6 22GY
G3 20BK/PK
G2 22VT
G19 20LG/OR
L62 18BR/RD
Z1 20BK
L63 18DG/RD
L34 20RD/OR
13
12
11
10
9
8
7
6
5
4
3
2
1
CAV
VTSS INDICATOR LAMP DRIVER
FUSED B (+)
SERVICE ENGINE SOON INDICATOR LAMP DRIVER
RIGHT TURN SIGNAL
GROUND
LEFT TURN SIGNAL
FUSED HIGH BEAM RELAY OUTPUT
CIRCUIT FUNCTION
SWITCH
MEMORY SET
BLUE
5 6 4
1 2 3
P23 20PK/RD
P22 20PK/BK
P24 20PK/WT
Z1 20BK
6
5
4
3
2
1
CAV
MEMORY NO. 2
MEMORY SET
MEMORY NO. 1
GROUND
-
-
CIRCUIT
-
-
FUNCTION
MODULE - C3
MEMORY SEAT/MIRROR
21
10
11
NATURAL
1
P29 20BR/WT
P25 22VT/RD
P47 22LB
P40 22GY/LB
P15 22YL/LB
P11 22YL/WT
P19 22YL/LG
P9 20RD
P28 20BR/RD
P26 22BR
P27 22LB/RD
P48 22GY/WT
P17 22RD/LB
P13 22RD/WT
P21 22RD/LG
21
20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
CAV
6 VOLT SUPPLY
SEAT HORIZONTAL POSITION SENSE
SEAT RECLINER POSITION SENSE
FUSED B (+)
SEAT FRONT VERTICAL POSITION SENSE
SEAT REAR VERTICAL POSITION SENSE
-
-
-
-
-
-
CIRCUIT
-
-
-
-
-
-
-
FUNCTION
J988W-3 NSGS8058

SWITCH
MULTI-FUNCTION
8 12
7
BLACK
1
L324 22WT/LG
V10 20BR
L94 20OR/WT
L93 22PK
Z1 18BK
F1 20DB
V52 20DG//YL
V16 20WT
L305 22LB/WT
L302 22LB/YL
L91 22DB/PK
12
11
10
9
8
7
6
5
4
3
2
1
CAV
HIGH BEAM RELAY CONTROL
FRONT WASHER MOTOR CONTROL
LOW BEAM RELAY CONTROL
HIGH/LOW BEAM RELAY CONTROL
GROUND
FUSED B(+)
WIPER MUX SIGNAL
HIGH SPEED RELAY DRIVER
RIGHT TURN SIGNAL SENSE
LEFT TURN SIGNAL SENSE
COMBO FLASHER SWITCHED GROUND
-
CIRCUIT
-
FUNCTION
ACTUATOR
MODE DOOR
5
BLACK
1
C35 20DG/YL
C57 20DB/GY
C37 20YL
C26 20PK/DB
C34 20DB/WT
5
4
3
2
1
CAV
MODE DOOR DRIVER
SENSOR GROUND
MODE DOOR FEEDBACK SIGNAL
5 VOLT SUPPLY
DOOR COMMON
CIRCUIT FUNCTION
FUSED RIGHT HIGH BEAM OUTPUT L34 20RD/OR
7 13
1 6
G2 22VT 1
2 G19 20LG/OR
3 L63 18DG/RD LEFT TURN SIGNAL
6
L62 18BR/RD RIGHT TURN SIGNALS
GROUND Z1 20BK
5
4
G69 22BK/OR 7
8 M1 20PK
9 R41 18BK/OR
V23 18BR/PK 10
13 G3 20BK/PK
ENGINE OIL PRESSURE SWITCH SENSE G6 22GY 12
G9 20GY/BK RED BRAKE WARNING LAMP DRIVER 11
FUSED B(+)
(RHD)
MESSAGE CENTER
VTSS INDICATOR LAMP DRIVER
NSGS8059 J988W-3

BLACK
NEEDLE MOVEMENT SENSOR (-) K68 18LG/YL 2
1 K67 18BR/BK NEEDLE MOVEMENT SENSOR (+)
(DIESEL)
SENSOR
NEEDLE MOVEMENT
2 1
J01D P30
14
7
8
1
8 14
1
BLACK BLACK
7
* REAR A/C
C21 20DB/OR
C102 20LG*
C62 20DB/PK*
C61 20DB*
C37 20YL
C36 20RD/WT
C35 20DG/YL
C34 20DB/WT
C33 20DB/RD
C32 20GY/DB
C57 20DB/GY
C26 20PK/DB
14
13
12
11
10
9
8
7
6
5
4
3
2
1
CAV
-
-
CIRCUIT
C21 22DB/OR
C102 22LG
C62 22DB/PK
C61 22DB
C37 22YL
C36 22RD/WT
C35 22DG/YL
C34 22DB/WT
C33 22DB/RD
C32 22GY/DB
C57 22DB/GY
C26 22PK/DB
14
13
12
11
10
9
8
7
6
5
4
3
2
1
CAV
-
-
CIRCUIT
CONSOLE
OVERHEAD
RED
5 6 4
1 2 3
D1 18VT/BR
G31 20VT/LG
V23 18BR/PK
Z2 18BK/LG
G32 20BK/LB
D2 18WT/BK
6
5
4
3
2
1
CAV
CCD BUS(+)
AMBIENT TEMPERATURE SENSOR SIGNAL
FUSED IGN. (ST-RUN)
GROUND
SENSOR GROUND
CCD BUS(-)
FUNCTION CIRCUIT
SPEED SENSOR
OUTPUT SHAFT
2 1
GRAY
T14 18LG/WT
T13 18DB/BK
2
1
CAV
OUTPUT SHAFT SPEED SIGNAL (+)
SPEED SENSOR GROUND
CIRCUIT FUNCTION
J988W-3 NSGS8060

ARM/DISARM SWITCH
PASSENGER DOOR
2 1
BLACK
P96 20WT/LG
Z2 20BK/LG
2
1
CAV
GROUND
CIRCUIT FUNCTION
AIRBAG SQUIB
PASSENGER
4 1
YELLOW
R42 18BK/YL
R44 18DG/YL
4
3
2
1
CAV
-
-
CIRCUIT
-
-
FUNCTION
(MTX)
POSITION SWITCH
PARK/NEUTRAL
3 1
BLACK
F11 18RD/WT
T41 18BK/WT
T3 18VT
3
2
1
CAV
PARK/NEUTRAL POSITION SWITCH SENSE
PARK/NEUTRAL POSITION SWITCH OUTPUT
CIRCUIT FUNCTION
(EATX)
POSITION SWITCH
PARK/NEUTRAL
1 3
BLACK
F20 18WT
T41 18BK/WT
L1 18VT/BK
3
2
1
CAV
PARK/NEUTRAL POSITION SWITCH SENSE
BACK-UP LAMP RELAY OUTPUT
CIRCUIT FUNCTION
(RHD)
8
7
8 Z1 18BK
M1 22PK 7
L91 20DB/PK
X12 20RD/WT
8
3
4
1
P50
5
6
4
3
2
1
D1 20VT/BR 1
2
3
G96 22LG/RD
D2 20WT/BK
4 F11 20RD/WT
6
5
NATURAL
-
-
-
-
-
-
-
-
NSGS8061 J988W-3

COURTESY LAMP
PASSENGER DOOR
1
BLACK
2
2
Z1 20BK
Z1 20BK
M11 20PK/LB 1
CAV
GROUND
CIRCUIT FUNCTION
LOCK MOTOR
PASSENGER DOOR
1
BLACK
2
F133 20BR
F136 20VT/YL
2
1
CAV
FUSED DOOR LOCK RELAY OUTPUT
FUSED DOOR UNLOCK RELAY OUTPUT
CIRCUIT FUNCTION
LOCK SWITCH
PASSENGER DOOR
3 1
BLACK
Z2 20BK/LG*
Z2 20BK/LG
P96 20WT/LG*
P96 20WT/LG
E2 20OR
E2 20OR
3
2
1
CAV
GROUND
PANEL LAMPS FEED
CIRCUIT FUNCTION
FUNCTION CIRCUIT
HEATED SEAT DRIVER
GROUND
CAV
A
B
P88 18RD/WT
Z1 18BK
SEAT BACK
PASSENGER HEATED
FUNCTION CIRCUIT
HEATED SEAT DRIVER
HEATED SEAT DRIVER
CAV
P87 18RD/WT
P88 18RD/WT
P89 20BK/RD
Z1 18BK
A
B
C
PASSENGER HEATED
SEAT CUSHION
D
HEATED SEAT BACK
GROUND
FUSED B(+)
PASSENGER HEATED SEAT SWITCH
D
SEAT MODULE
PASSENGER HEATED
C
B
A
F35 18RD
P8 20WT/BK
P86 20VT
P87 18RD/WT
CAV
HEATED SEAT DRIVER
CIRCUIT FUNCTION
P89 20BK/RD E HEATED SEAT BACK
F Z1 18BK GROUND
* RKE
J988W-3 NSGS8062

MIRROR - C2
PASSENGER POWER
6 5
BLUE
4
2 1 3
P68 20DG/RD
P66 20WT/BK
P67 20YL/RD
3
2
1
CAV
PASSENGER MIRROR POSITION (HORIZONTAL)
PASSENGER MIRROR POSITION COMMON
PASSENGER MIRROR POSITION (VERTICAL)
CIRCUIT FUNCTION
MIRROR - C1
PASSENGER POWER
RED
5 6 4
1 2 3
Z1 20BK
C16 20LB/YL
P70 20WT
P72 20YL/BK
P74 20DB
6
5
4
3
2
1
CAV
GROUND
FUSED B(+)
MIRROR SWITCH COMMON
MIRROR SWITCH OUTPUT (VERTICAL)
MIRROR SWITCH OUTPUT (HORIZONTAL)
-
CIRCUIT
-
FUNCTION
4 - -
5 P159 20DG* PASSENGER MIRROR UNFOLD SIGNAL
6 P160 20LB* PASSENGER MIRROR FOLD SIGNAL
* BUILT-UP-EXPORT
-
D
SEAT SWITCH
PASSENGER HEATED
C
B
A
F20 20WT
-
F20 20WT
P86 20VT
CAV
CIRCUIT FUNCTION
Z1 18BK E GROUND
F P8 20WT/BK PASSENGER HEATED SEAT SWITCH
** RKE
NSGS8063 J988W-3

HORIZONTAL MOTOR
PASSENGER SEAT
B
BLACK
A
P14 14YL/LB
P16 14RD/LB
B
A
CAV
CIRCUIT FUNCTION
MOTOR
FRONT VERTICAL
PASSENGER SEAT
B
BLACK
A
P20 14RD/LG
P18 14YL/LG
B
A
CAV
CIRCUIT FUNCTION
WINDOW SWITCH
PASSENGER POWER
8
4
5
BLACK
1
Q12 14BR
Z1 20BK
E2 20OR
Q22 14VT
Q16 12BR/WT
Q26 12VT/WT
F55 12TN/DG
8
7
6
5
4
3
2
1
CAV
RIGHT FRONT WINDOW (UP)
GROUND
PANEL LAMPS FEED
RIGHT FRONT WINDOW (DOWN)
RIGHT FRONT WINDOW (UP)
RIGHT FRONT WINDOW (DOWN)
FUSED IGNITION SWITCH OUTPUT (RUN/ACC)
-
CIRCUIT
-
FUNCTION
SWITCH
POWER SEAT
PASSENGER
10
5
6
1
GREEN
P18 14YL/LG
P10 14YL/WT
P12 14RD/WT
P20 14RD/LG
P14 14YL/LB
F35 14RD
P42 14GY/WT
P16 14RD/LB
P44 14GY/LB
Z1 14BK
10
9
8
7
6
5
4
3
2
1
CAV
FUSED (B+)
GROUND
CIRCUIT FUNCTION
J988W-3 NSGS8064

CENTER - C1
DISTRIBUTION
POWER
1
4
3
NATURAL
6
A4 12BK/RD
L7 12BK/YL
C71 12DB
6
5
4
3
2
1
CAV
FUSED B (+)
TAIL, LICENSE, SIDE MARKER LAMP, PARK LAMP FEED
BLOWER MOTOR FEED FROM ATC/RELAY
-
-
-
CIRCUIT
-
-
-
FUNCTION
RECLINER MOTOR
PASSENGER SEAT
B
BLACK
A
P44 14GY/LB
P42 14GY/WT
B
A
CAV
CIRCUIT FUNCTION
REAR VERTICAL MOTOR
PASSENGER SEAT
B
BLACK
A
P10 14YL/WT
P12 14RD/WT
B
A
CAV
CIRCUIT FUNCTION
WINDOW MOTOR
PASSENGER
RED
2 1
Q21 16WT
Q11 16LG
2
1
CAV
DRIVER WINDOW (DOWN)
DRIVER WINDOW (UP)
CIRCUIT FUNCTION
NSGS8065 J988W-3

POWER
DISTRIBUTION
CENTER - C3
LOW BEAM RELAY DRIVER L193 20OR/WT**
6
1
10
5
DK. GREEN
L97 18PK/DB
F32 18PK/DB
L94 20OR/WT*
A20 12RD/DB
M1 20PK
L324 20WT/LG
L44 20VT/RD
10
9
8
7
6
5
4
3
2
1
CAV
FUSED B (+)
LOW BEAM RELAY DRIVER
FUSED B (+)
FUSED B (+)
HIGH BEAM RELAY DRIVER
-
-
-
CIRCUIT
-
-
-
FUNCTION
* DODGE/PLYMOUTH OR BUILT-UP-EXPORT
** CHRYSLER (PREMIUM)
CENTER - C2
DISTRIBUTION
POWER
6
1
10
5
ORANGE
F30 16RD
F1 20DB
X2 18DG/RD
A141 16DG/WT
F87 18WT/BK
F20 20WT
X4 20GY/OR
F45 20YL/RD
F41 20PK/VT
10
9
8
7
6
5
4
3
2
1
CAV
CIGAR AND ACCESSORY RELAY OUTPUT
WIPE FEED
HORN RELAY OUTPUT
FUSED IGN. (ST-RUN)
IGNITION FEED FOR EVIC
HORN RELAY CONTROL
FUSED IGNITION SWITCH OUTPUT (START)
FUSED B (+)
-
CIRCUIT
-
FUNCTION
EATX
MTX
3 T141 20YL/RD CLUTCH INTERLOCK SWITCH
J988W-3 NSGS8066

CENTER - C6
DISTRIBUTION
POWER
K51 20DB/YL ASD RELAY CONTROL
A/C COMPRESSOR CLUTCH RELAY CONTROL C13 20DB/OR
GROUND Z1 20BK
FUSED IGNITION "C" (7.5A) A142 18DG/OR
10 6
1 5
LT. GREEN
A14 18RD/WT
K51 18DB/YL
C13 18DB/OR
F87 18WT/BK
A142 18DG/OR
K90 18TN
K31 18BR
C3 18DB/BK
F87 18BK/WT
10
9
8
7
6
5
4
3
2
1
CAV
FUSED B(+)
ASD RELAY CONTROL
FUSED IGNITION SWITCH OUTPUT (RUN/START)
ASD RELAY OUTPUT
ENGINE STARTER MOTOR RELAY CONTROL
FUEL PUMP RELAY CONTROL
A/C COMPRESSOR CLUTCH RELAY OUTPUT
FUSED IGNITION "C" (7.5A)
-
FUNCTION
-
CIRCUIT
** BUILT-UP-EXPORT
DIESEL
GAS
1
3
7
8
FUSED IGNITION SWITCH OUTPUT (RUN) F23 18DB/YL**
CENTER - C5
DISTRIBUTION
POWER
FUSED IGNITION SWITCH OUTPUT (ST-RUN)
2
F14 18LG/YL**
HIGH BEAM RELAY OUTPUT L34 20RD/OR
10 6
1 5
LT. GRAY
F23 20DB/YL*
L9 18BK/WT
L43 18VT
V14 18RD/VT
L34 20RD/OR
V16 20WT
V4 12RD/YL
V3 12BR/WT
F14 20LG/YL*
L33 20RD
10
9
8
7
6
5
4
3
1
CAV
FUSED IGNITION SWITCH OUTPUT (RUN)
FUSED HAZARD FLASHER FEED (DEDICATED)
LOW BEAM RELAY OUTPUT
WIPER ON RELAY DRIVER
HIGH BEAM RELAY OUTPUT
WIPER HIGH/LOW RELAY DRIVER
WIPER HIGH/LOW RELAY OUTPUT (HIGH)
WIPER HIGH/LOW RELAY OUTPUT (LOW)
HIGH BEAM RELAY OUTPUT
CIRCUIT FUNCTION
CENTER - C4
DISTRIBUTION
POWER
1
4
3
BLACK
6
A10 12RD/DG
A2 12PK/BK
A1 12RD
Z1 18BK
A22 12BK/OR
6
5
4
3
2
1
CAV
FUSED LINK TO ABS PUMP MOTOR RELAY
BATTERY FEED TO IGNITION SWITCH
FUSED B (+)
GROUND
IGNITION SWITCH RUN ONLY FEED
-
CIRCUIT
-
FUNCTION
NSGS8067 J988W-3

CENTER - C7
DISTRIBUTION
POWER
6 4
3 1
GRAY
A16 12GY
T40 12BR
6
5
4
3
2
1
CAV
FUSED B(+)
STARTER MOTOR RELAY OUTPUT
-
FUSED B(+)
-
-
FUNCTION
-
A17 12RD/BK*
-
-
CIRCUIT
* DIESEL
POWER
DISTRIBUTION
CENTER - C8
Z16 18BK
TRANSMISSION CONTROL RELAY CONTROL
10 6
1 5
AQUA
A5 18RD/DB
F45 18YL/RD
T15 18LG
T16 18RD
10
9
8
7
6
5
4
3
2
1
CAV
FUSED B(+)
FUSED B(+)
GROUND
TRANSMISSION CONTROL RELAY OUTPUT
-
-
-
-
-
FUNCTION
-
-
-
-
-
CIRCUIT
(BUILT-UP-EXPORT)
2 1
GROUND Z1 20BK
POWER FOLDING MIRROR INPUT P136 20YL
1
2
POWER FOLDING
MIRROR SWITCH
BLACK
POWER
MIRROR
SWITCH
BLACK
7
1
13
6
P72 20YL/BK
P71 20YL
Z1 20BK
F41 20PK/VT
P74 20DB
P75 20DB/WT
P73 20YL/PK
E2 20OR
P70 20WT
13
12
11
10
9
8
7
6
5
4
3
2
1
CAV
RIGHT VERTICAL
LEFT VERTICAL
GROUND
FUSED B (+)
RIGHT HORIZONTAL
LEFT HORIZONTAL
LEFT COMMON
PANEL LAMPS FEED
RIGHT COMMON
-
-
-
-
FUNCTION
-
-
-
-
CIRCUIT
J988W-3 NSGS8068

POWER SEAT
CIRCUIT BREAKER
2 1
GRAY
2
F35 14RD*
F35 14RD
A3 12PK/BK 1
CAV
FUSED B(+)
FUSED B(+)
FUNCTION CIRCUIT
* MEMORY SEAT
(DIESEL)
MODULE
CONTROL
POWERTRAIN
46
68
23
1
CONTINUED ON NEXT PAGE
V37 20RD/LG SPEED CONTROL SWITCH SIGNAL
- -
- -
- -
- -
SLEEVE POSITION SENSOR K134 20LB/BK
A/C COMPRESSOR CLUTCH RELAY CONTROL C13 20DB/OR
SPEED CONTROL LAMP DRIVER V38 20LB/RD
GROUND Z12 16BK/TN
DIESEL POWER RELAY OUTPUT A142 16DG/OR
-
ENGINE SPEED SENSOR RETURN K3 20BK/VT
5 VOLT SUPPLY K7 20OR
- -
ACCELERATOR PEDAL SENSOR SIGNAL
K22 20OR/DB
K2 20TN/BK
NEEDLE MOVEMENT SENSOR SIGNAL K67 20BR/BK
- -
- -
FUEL QUANTITY ACTUATOR SIGNAL K140 18TN/WT
GROUND Z12 16BK/TN
ENGINE SPEED SENSOR SIGNAL K159 20VT/RD
FUNCTION
-
-
-
-
CIRCUIT
-
-
-
ENGINE STARTER MOTOR RELAY CONTROL
LOW SPEED RADIATOR FAN RELAY NO. 2 CONTROL
CONTROL SLEEVE POSITION SENSOR
ENGINE SPEED SENSOR FEED
NEEDLE MOVEMENT SENSOR RETURN
A/C PRESSURE SWITCH SIGNAL
CLUTCH SWITCH SIGNAL
GLOW PLUG LAMP DRIVER
SENSOR GROUND
A/C SWITCH SIGNAL
BOOST PRESSURE SENSOR SIGNAL
CAV
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
K90 20TN
K140 18TN/WT
C24 20DB/PK
K57 20LG/OR
K24 18GY/BK
K68 20LG/YL
C18 20DB
K119 20LG/BK
K29 20WT/PK
G85 20OR/BK
K4 20BK/LB
C103 20DG/LB
K1 20DG/RD
EGR SOLENOID CONTROL K35 20GY/YL
FUSED IGNITION (ST-RUN) F87 18WT/BK
(2.0L/2.4L)
PRESSURE SWITCH
POWER STEERING
2 1
BLACK
Z1 18BK
K10 18DB/OR
2
1
CAV
GROUND
POWER STEERING PRESSURE SWITCH SENSE
FUNCTION CIRCUIT
BRAKE SWITCH SENSE
NSGS8069 J988W-3

53 FUEL SHUT OFF SIGNAL K153 18OR/DG
54 - -
K167 20BR/YL ACCELERATOR PEDAL SENSOR GROUND 55
51 SLEEVE POSITION SENSOR (+) K126 20LG
52 K135 20WT/BK SHUT DOWN SOLENOID CONTROL
FUEL TIMING SOLENOID CONTROL K152 20WT/DG 50
SLEEVE POSITION SENSOR (+) K140 18TN/WT 49
48 C137 20YL HIGH SPEED RADIATOR FAN RELAY NO. 1 AND 3 CONTROL
44
45
46
A142 16DG/OR DIESEL POWER RELAY OUTPUT
GROUND Z12 16BK/TN
47 - -
VEHICLE SPEED SENSOR SIGNAL G7 18WT/OR 43
K51 20DB/YL DIESEL POWER RELAY 42
41 K9 20LB
5 VOLT SUPPLY
- - 56
59 G55 20OR/BK
60 - -
- - 58
K6 20VT/WT 5 VOLT SUPPLY 57
61 D21 20PK
- - 66
62 - -
63 K156 20GY FUEL TEMPERATURE SENSOR SIGNAL
LOW IDLE POSITION SWITCH SIGNAL K151 20WT 65
K21 20BK/RD INTAKE AIR TEMPERATURE SENSOR SIGNAL 64
SCI TRANSMIT
ENGINE DISABLE SIGNAL
L50 18WT/TN STOP LAMP SWITCH SIGNAL
67 - -
DIESEL POWER RELAY OUTPUT A142 16DG/OR 68
(CONTINUED)
J988W-3 NSGS8070

MODULE - C1
CONTROL
POWERTRAIN
- -
K90 18TN ENGINE STARTER MOTOR RELAY CONTROL
C103 18DG/LB A/C SWITCH SIGNAL
KNOCK SENSOR SIGNAL K42 18DB/LG
- -
BLACK
10
20
30
40
1
11
21
31
K35 18GY/YL
K1 18DG/RD
K22 18OR/DB
K44 18TN/YL
K24 18GY/BK
K41 18BK/DG
K2 18TN/BK
G3 18BK/PK
F87 18WT/BK
K12 18TN/WT
K14 18LB/BR
K38 18GY
K58 18BR/DB
K11 18WT/DB
K19 18GY/RD
Z12 18BK/TN
K20 18DG
K13 18YL/WT
A142 18DG/OR
V32 18YL/RD
K17 18DB/TN
K18 18RD/YL
40
39
38
37
36
35
34
33
32
31
30
29
28
27
26
25
24
23
22
21
20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
CAV
EGR SOLENOID CONTROL
MANIFOLD ABSOLUTE PRESSURE SENSOR SIGNAL
THROTTLE POSITION SENSOR SIGNAL
CAMSHAFT POSITION SENSOR SIGNAL
HEATED OXYGEN SENSOR SIGNAL
INJECTOR NO. 5 DRIVER (3.3L/3.8L)
INJECTOR NO. 6 DRIVER (3.3L/3.8L)
GROUND
GENERATOR FIELD DRIVER
AUTOMATIC SHUT DOWN RELAY OUTPUT
SPEED CONTROL ON/OFF SWITCH SENSE
IGNITION COIL NO. 3 DRIVER (3.3L/3.8L)
-
-
-
-
-
-
-
-
-
-
-
-
CIRCUIT
-
-
-
-
-
-
-
-
-
-
-
-
FUNCTION
K21 18BK/RD* INTAKE AIR TEMPERATURE SENSOR SIGNAL
* 2.0L
NSGS8071 J988W-3

MODULE - C2
CONTROL
POWERTRAIN
K70 18VT/RD PULSE WIDTH MODULATED PURGE CURRENT SENSE
- -
80 71
61
51
41
70
60
50
GRAY
V35 18LG/RD
K106 18WT/DG
T41 18BR/YL
D20 18LG
K31 18BR
K173 14LG/DB
K107 18YL/BK
K52 18PK/BK
K51 18DB/YL
G7 18WT/OR
D21 18PK
C13 18DB/OR
T10 18YL/DG
K29 18WT/PK
K6 18VT/WT
D2 18WT/BK
D1 18VT/BR
K59 18VT/BK
K39 18GY/RD
V36 18TN/RD
K141 18TN/WT
Z12 18BK/TN
K60 18YL/BK
K40 18BR/WT
A14 18RD/WT
K7 18OR
K4 18BK/LB
C18 18DB
V37 18RD/LG
80
79
78
77
76
75
74
73
72
71
70
69
68
67
66
65
64
63
62
61
60
59
58
57
56
55
54
53
52
51
50
49
48
47
46
45
44
43
42
41
CAV
SPEED CONTROL VENT SOLENOID CONTROL
EVAP LEAK DETECTION PUMP SOLENOID CONTROL
TRANSMISSION RANGE SWITCH T41 SENSE
SCI RECEIVE
FUEL PUMP RELAY CONTROL
RADIATOR FAN RELAY CONTROL
EVAP LEAK DETECTION PUMP STROKE SENSE
EVAP/PURGE SOLENOID CONTROL
AUTOMATIC SHUT DOWN RELAY CONTROL
SCI TRANSMIT
TORQUE MANAGEMENT REQUEST SENSE
5 VOLT SUPPLY
CCD BUS (-)
CCD BUS (+)
IDLE AIR CONTROL MOTOR NO. 4 DRIVER
SPEED CONTROL VACUUM SOLENOID CONTROL
HEATED OXYGEN SENSOR SIGNAL
GROUND
FUSED B(+)
8 VOLT SUPPLY
SENSOR GROUND
A/C PRESSURE SWITCH SIGNAL
-
-
-
-
-
-
-
CIRCUIT
-
-
-
-
-
-
-
FUNCTION
EATX
- -
* 3.3L/3.8L ENGINE
K50 18YL/WT* FLEXIBLE FUEL SENSOR SIGNAL
FUNCTION CIRCUIT
FUSED B(+)
IGNITION SWITCH OUTPUT (OFF/RUN/START)
CAV
1
2
M1 20PK
A81 20DG/RD
BLACK
2 1
PRNDL FEED
J988W-3 NSGS8072

(GAS)
FAN RELAY
RADIATOR
4 1
BLACK
A16 12GY
C23 12DG
K173 14LG/DB
Z1 14BK
4
3
2
1
CAV
FUSED B(+)
LOW SPEED RADIATOR FAN RELAY OUTPUT
GROUND
CIRCUIT FUNCTION
NO.2
RADIATOR FAN
2 1
BLACK
Z1 12BK
C23 12DG
2
1
CAV
GROUND
CIRCUIT FUNCTION
NO. 1
RADIATOR FAN
2 1
BLACK
Z1 12BK
C23 12DG
2
1
CAV
GROUND
CIRCUIT FUNCTION
BLACK
RADIATOR FAN RELAY OUTPUT
HIGH SPEED RELAY OUTPUT C116 12LG/WT
C25 12YL 4
3
4 1 RADIATOR FAN RELAY CONTROL C27 12DB/PK 2
1 Z1 12BK
GROUND
(DIESEL)
DISCONNECT
RADIATOR FAN
PRNDL SWITCH
3
NATURAL
1
T1 18LG/BK
T42 18VT/WT
Z13 18BK/RD
3
2
1
CAV
PRNDL SWITCH SENSE
PRNDL SWITCH GROUND
GROUND
CIRCUIT FUNCTION
NSGS8073 J988W-3

HIGH SPEED RADIATOR FAN RELAY CONTROL C27 12DB/PK 5
NATURAL
1 3
6 4
7 9
2
5
8
FAN RELAY
NO. 1
(DIESEL)
RADIATOR
GROUND
Z1 12BK 2
8
6 C137 20YL
C116 12LG/WT
HIGH SPEED RADIATOR FAN RELAY CONTROL
RADIO - C1
GRAY
7 1
3
2
M1 20PK
X12 18RD/WT
E2 20OR
E17 20YL/BK
X56 20DB/RD*
X56 20DB/RD
X55 20BR/RD*
X55 20BR/RD
7
6
5
4
1
CAV
FUSED B(+)
PANEL LAMPS FEED
RIGHT DOOR SPEAKER (-)
RIGHT DOOR SPEAKER (-)
LEFT DOOR SPEAKER (-)
LEFT DOOR SPEAKER (-)
-
CIRCUIT
-
FUNCTION
1 3
6 4
7 9
2
5
8
FAN RELAY
NO. 3
(DIESEL)
RADIATOR
C27 12DB/PK 2
8
6 C137 20YL
A17 12RD/BK FUSED B(+)
HIGH SPEED RADIATOR FAN RELAY CONTROL
NATURAL
1 3
6 4
7 9
2
5
8
FAN RELAY
NO. 2
(DIESEL)
RADIATOR
RADIATOR FAN RELAY OUTPUT
C25 12YL 2
8
6 C24 20DB/PK
A16 12GY FUSED B(+)
LOW SPEED RADIATOR FAN RELAY CONTROL
* PREMIUM
HIGH SPEED RELAY OUTPUT
J988W-3 NSGS8074

FUNCTION CIRCUIT
RIGHT REAR SPEAKER (+)
LEFT DOOR SPEAKER (+)
LEFT DOOR SPEAKER (+)
RIGHT DOOR SPEAKER (+)
RIGHT DOOR SPEAKER (+)
RIGHT REAR SPEAKER (-)
CAV
1
2
3
4
5
6
7
X51 20BR/YL
X52 20DB/WT
X53 20DG
X53 20DG*
X54 20VT
X54 20VT*
X57 20BR/LB
X58 20DB/OR
7
BLACK
1
X60 20RD/DG RADIO 12 VOLT OUTPUT
RADIO - C3
1 2
BLACK
D2 20WT/BK
D1 20VT/BR
2
1
CAV
CCD BUS(-)
CCD BUS(+)
CIRCUIT FUNCTION
RADIO - C2
RADIO CHOKE
1 2
LT.GRAY
X13 16RD/DG
X1 16DG/RD
2
1
CAV
RADIO CHOKE OUTPUT
CIRCUIT FUNCTION
DUAL ZONE A/C ACTUATOR
REAR A/C-HEATER UNIT
CIRCUIT
-
-
-
-
FUNCTION
-
-
-
-
A/C MODE DOOR DRIVER (A)
REAR BLOWER RELAY OUTPUT
REAR BLOWER MEDIUM SPEED
REAR BLOWER HIGH SPEED
CAV
1
2
3
4
5
6
7
8
9
10
C34 20DB/WT
C61 20DB
C40 12BR/WT
C65 14BK/OR
C60 16BK/LB
C70 12DG
LT. GREEN
5
10
1
6
* PREMIUM
NSGS8075 J988W-3

LIGHTER/POWER OUTLET
REAR CIGAR
FUSED B(+) F30 16RD
3
3
1 2
RED
GROUND 16BK Z1
2 - -
1
FUNCTION CIRCUIT CAV
SWITCH
REAR CONTROL
REAR BLOWER
8
4
5
BLACK
1
E2 20OR
C50 12BK/LG
Z1 18BK
C70 12DG
C65 14BK/OR
C60 16BK/LB
8
7
6
5
4
3
2
1
CAV
PANEL LAMPS FEED
REAR BLOWER LOW SPEED
GROUND
-
-
FUNCTION
-
-
CIRCUIT
CONTROL SWITCH
REAR BLOWER FRONT
1 8
BLACK
E2 20OR
Z1 12BK
C50 12BK/LG
C60 16BK/LB
C70 12DG
8
7
6
5
4
3
2
1
CAV
PANEL LAMPS FEED
GROUND
REAR BLOWER LOW SPEED
-
-
-
FUNCTION
-
-
-
CIRCUIT
J988W-3 NSGS8076

MOTOR
REAR WIPER
3 1
BLACK
V13 18BR/LG
V23 18BR/PK
Z1 18BK
3
2
1
CAV
REAR WIPER MOTOR CONTROL
GROUND
FUNCTION CIRCUIT
MOTOR
REAR WASHER
BLACK
A B
V20 20BK/WT
F1 20DB
B
A
CAV
FUNCTION CIRCUIT
LAMP
REAR DOME
BLACK
- -
READING LAMP FEED
CIRCUIT CAV
1
2 M113 20LB/PK
M20 20BR 3
3 1
ENTRY MODULE
REMOTE KEYLESS
RED
5 6 4
1 2 3
G96 20LG/RD
D9 22GY/BK
Z2 20BK/LG
M1 20PK
6
5
4
3
2
1
CAV
RKE INTERFACE
RKE MODULE PROGRAM ENABLE
GROUND
FUSED B(+)
-
-
CIRCUIT
-
-
FUNCTION
DOOR ACTUATOR
RECIRCULATION
1 5
NATURAL
C32 20GY/DB
C34 20DB/WT
5
4
3
2
1
CAV
RECIRCULATION DOOR DRIVER
COMMON DOOR DRIVER
-
-
-
CIRCUIT
-
-
-
FUNCTION
NSGS8077 J988W-3

RELAY
RIGHT COMBINATION
- -
BLACK
4
2
3
5
RIGHT TURN SIGNAL 1
L605 18DG
L50 18WT/TN
Z1 18BK
L62 18BR/RD
L62 18BR/RD
5
4
3
2
CAV
RIGHT TURN SIGNAL
GROUND
CIRCUIT FUNCTION
FOG LAMP
RIGHT
FOG LAMP RELAY OUTPUT L39 18LB**
GRAY*
1
PURPLE**
2
Z39 20BK
L39 18VT/RD*
2
1
CAV
FOG LAMP SWITCHED GROUND
FOG LAMP RELAY OUTPUT
CIRCUIT FUNCTION
BLACK
FOG LAMP SWITCHED GROUND Z39 20BK 2
1 F39 18PK/LG
FUSED PARK LAMP RELAY OUTPUT
RIGHT
FOG LAMP
(BUILT-UP-EXPORT)
1 2
(PREMIUM)
SPEAKER
RIGHT DOOR
X56 20DB/RD RIGHT FRONT SPEAKER (-)
RADIO CHOKE OUTPUT X13 16RD/DG
6
5
3
6 4
1
BLACK
X155 20BR/WT
X54 20VT
X15 16BK/DG
X153 20WT/BR
4
3
2
1
CAV
RIGHT FRONT I/P SPEAKER (-)
RIGHT FRONT SPEAKER (+)
RIGHT I/P SPEAKER (+)
FUNCTION CIRCUIT
PANEL SPEAKER
RIGHT FRONT
3
4
X153 20WT/BR
-
RIGHT FRONT I/P SPEAKER (+)
-
BLACK
4 1
-
X155 20BR/WT
2
1
CAV
-
RIGHT FRONT I/P SPEAKER (-)
CIRCUIT FUNCTION
(TRAILER TOW)
(PREMIUM)
RHD
LHD
DIESEL
* DODGE/PLYMOUTH
** CHRYSLER
X154 20WT/VT RIGHT FRONT I/P SPEAKER (+)
X156 20VT/WT RIGHT FRONT I/P SPEAKER (-)
GRAY
X156 20VT/WT RIGHT FRONT I/P SPEAKER (-)
X154 20WT/VT RIGHT I/P SPEAKER (+)
J988W-3 NSGS8078

3 1
(BUILT-UP-EXPORT)
RIGHT FRONT PARK/
TURN SIGNAL LAMP
BLACK
FUSED B(+)
L78 20DG/YL 1
2 Z1 18BK
3 L60 18TN RIGHT TURN SIGNAL
GROUND
SIGNAL LAMP
PARK/TURN
RIGHT FRONT
3 1
BLACK
Z1 20BK
L78 20DG/YL
L60 18TN
3
2
1
CAV
GROUND
FUSED B(+)
RIGHT TURN SIGNAL
CIRCUIT FUNCTION
RIGHT FRONT
SPEAKER
(BASE)
1 4
BLACK
FUNCTION CIRCUIT
-
RIGHT FRONT SPEAKER (-)
CAV
1
2
-
X56 20DB/RD
RIGHT FRONT SPEAKER (+)
-
X54 20VT
- 4
3
3
2
1
FUSED RIGHT HIGH BEAM RELAY OUTPUT
L34 20RD/OR 1
2 L44 20VT/RD
3 Z1 20BK GROUND
RIGHT HEADLAMP
(BUILT-UP-EXPORT)
BLACK
WHEEL SPEED SENSOR
RIGHT FRONT
1 2
BLACK
B7 18WT
B6 18WT/DB
2
1
CAV
RIGHT FRONT WHEEL SPEED SENSOR (+)
RIGHT FRONT WHEEL SPEED SENSOR (-)
CIRCUIT FUNCTION
NSGS8079 J988W-3

2
1 3
BLACK
L34 20RD/OR
Z1 20BK
L44 20VT/RD
3
2
1
CAV
FUSED RIGHT HIGH BEAM OUTPUT
GROUND
CIRCUIT FUNCTION
RIGHT HEADLAMP
B A
FUNCTION
A
CAV
L44 20VT/RD
CIRCUIT
B Z1 20BK GROUND
FLOOD LAMP
RIGHT LIFTGATE
1
BLACK
2
Z1 20BK
M11 20PK/LB
2
1
CAV
GROUND
CIRCUIT FUNCTION
HEADLAMP (CHRYSLER)
RIGHT HIGH
FUNCTION
B
A
CAV
Z1 20BK
L34 20RD/OR
CIRCUIT
GROUND
FUSED RIGHT HIGH BEAM OUTPUT B A
1 3
(BUILT-UP-EXPORT)
GROUND
Z1 20BK 1
2 L13 18BR/YL
3 L44 20VT/RD FUSED RIGHT LOW BEAM OUTPUT
RIGHT HEADLAMP
LEVELING MOTOR
HEADLAMP ADJUST SIGNAL
BLACK
RIGHT LOW
HEADLAMP (CHRYSLER)
J988W-3 NSGS8080

LAMP ASSEMBLY
RIGHT REAR
3
6
1
4
BLACK
Z1 20BK
L50 18WT/TN
L78 20DG/YL
L1 20VT/BK
L62 18BR/RD
6
5
4
3
2
1
CAV
GROUND
FUSED B(+)
BACK-UP LAMP FEED
RIGHT TURN SIGNAL
-
CIRCUIT
-
FUNCTION
(PREMIUM)
READING LAMP
RIGHT REAR
1 3
GRAY
F41 20PK/VT
M20 20BR
M113 20LB/PK
3
2
1
CAV
FUSED B(+)
READING LAMP FEED
FUNCTION CIRCUIT
PILLAR SPEAKER
RIGHT REAR
BLACK
2 1
X152 20DB/WT
X158 20DB/OR
2
1
CAV
RIGHT REAR PILLAR SPEAKER (-)
RIGHT REAR PILLAR SPEAKER (+)
CIRCUIT FUNCTION
(BUILT-UP-EXPORT)
LAMP ASSEMBLY
RIGHT REAR
3
6
1
4
BLACK
L50 18WT/TN
L62 18BR/RD
L1 20VT/BK
L78 20DG/YL
Z1 20BK
6
5
4
3
2
1
CAV
RIGHT TURN SIGNAL
BACK-UP LAMP FEED
FUSED B(+)
GROUND
L36 20LG
CIRCUIT
REAR FOG LAMP
FUNCTION
SWITCH
DOOR AJAR
RIGHT REAR
2 3
1
NATURAL*
G76 18TN/YL
Z1 18BK
3
2
1
CAV
RIGHT REAR DOOR AJAR SWITCH SENSE
GROUND
-
CIRCUIT
-
FUNCTION
READING LAMP
RIGHT MID
3 1
GRAY
F41 20PK/VT
M20 20BR
M113 20LB/PK
3
2
1
CAV
FUSED B(+)
READING LAMP FEED
CIRCUIT FUNCTION
BLACK
* DIESEL
NSGS8081 J988W-3

SPEAKER
RIGHT REAR
RADIO CHOKE OUTPUT X13 16RD/DG*
RIGHT REAR SPEAKER (-) X152 20DB/WT*
6
5
6
3
4
1
BLACK
3
2
X158 20DB/OR*
X52 20DB/WT
X58 20DB/OR
X15 16BK/DG*
4
1
CAV
RIGHT REAR SPEAKER (-)
FUNCTION CIRCUIT
(RHD)
VENT MOTOR
RIGHT REAR
1 3
NATURAL
Q13 18DB
Q23 18RD/WT
3
2
1
CAV
RIGHT REAR VENT MOTOR (CLOSE)
RIGHT REAR VENT MOTOR (OPEN)
-
FUNCTION
-
CIRCUIT
(LHD)
VENT MOTOR
RIGHT REAR
1 3
NATURAL
Q14 18GY
Q24 18DG
3
2
1
CAV
RIGHT REAR VENT MOTOR (CLOSE)
RIGHT REAR VENT MOTOR (OPEN)
-
FUNCTION
-
CIRCUIT
2 1
RIGHT TURN SIGNAL
L62 18BR/RD 1
2 Z1 18BK GROUND
GRAY
SENSOR
WHEEL SPEED
RIGHT REAR
GRAY
2
B2 18YL
B1 18YL/DB
2
1
CAV
RIGHT REAR WHEEL SPEED SENSOR (+)
RIGHT REAR WHEEL SPEED SENSOR (-)
FUNCTION CIRCUIT
1
CONTACTS
SLIDING DOOR
RIGHT REAR
3 1
BLACK
F136 20VT/YL
F133 20BR/YL
3
2
1
CAV
UNLOCK RELAY OUTPUT
LOCK RELAY OUTPUT
-
FUNCTION
-
CIRCUIT
RIGHT REPEATER
LAMP
(BUILT-UP-EXPORT)
* PREMIUM
J988W-3 NSGS8082

SWITCH
STOP LAMP
1
6
GRAY
F32 18PK/DB
L50 18WT/TN
V30 20DB/RD*
V32 20YL/RD*
Z1 20BK
K29 20WT/PK
6
5
4
3
2
1
CAV
FUSED B(+)
SPEED CONTROL BRAKE SWITCH OUTPUT
GROUND
FUNCTION CIRCUIT
* GAS
DIMMING MODULE
SPEED CONTROL
4
BLACK
1
V32 20YL/RD
V38 20LB/RD
L97 29PK/DB
4
3
2
1
CAV
SPEED CONTROL RELAY CONTROL
-
FUNCTION
-
CIRCUIT
BLACK
(BUILT-UP-EXPORT)
6 1
MODULE
IMMOBILIZER
SENTRY KEY
1 F41 20PK/VT FUSED B(+)
2 Z2 20BK GROUND
3 F87 20WT/BK FUSED IGNITION (ST-RUN)
4 - -
5 D2 20WT/BK CCD BUS (-)
6 D1 20VT/BR CCD BUS (+)
SWITCH
SEAT BELT
2 1
BLACK
Z1 20BK
G10 18LG/RD
2
1
CAV
GROUND
SEAT BELT SWITCH SENSE
FUNCTION CIRCUIT
VANITY MIRROR LAMPS
RIGHT VISOR/
A B
BLACK
F41 20PK/VT
M20 20BR
B
A
CAV
FUSED B(+)
FUNCTION CIRCUIT
SIGNAL RELAY
STOP/TURN
RIGHT
BLACK
4
2
3
5
2
1
GROUND
L605 18DG
L62 18BR/RD
L74 18LG
Z1 18BK
Z1 18BK
L50 18WT/TN
L50 18WT/TN
5
4
3
CAV
RIGHT COMBINATION RELAY OUTPUT
RIGHT TURN SIGNAL
FUNCTION CIRCUIT
(TRAILER TOW)
NSGS8083 J988W-3

CONNECTOR
TRAILER TOW
CAP
L73 18YL
Z1 18WT
L78 18BR
L74 18LG
4
3
2
1
CAV
GROUND
FUSED B(+)
CIRCUIT FUNCTION
SWITCH
TRACTION CONTROL
E2 20OR
B27 20RD/YL
Z1 20BK
3
2
1
CAV
PANEL LAMP FEED
TRACTION CONTROL SWITCH SENSE
GROUND
CIRCUIT FUNCTION
3 1
BLACK
(EXCEPT 2.0L)
POSITION SENSOR
THROTTLE
K4 18BK/LB SENSOR GROUND
1 3
1
K22 18OR/DB THROTTLE POSITION SENSOR SIGNAL 2
K6 18VT/WT 5 VOLT SUPPLY 3
1
2
K4 18BK/LB CRANK POSITION SENSOR
THROTTLE POSITION SENSOR SIGNAL K22 18OR/DB
3 K6 18VT/WT 5V SUPPLY
(2.0L)
SENSOR
THROTTLE POSITION
WHITE
3 1
WHITE
J988W-3 NSGS8084

MODULE
CONTROL
TRANSMISSION
(CONTINUED ON NEXT PAGE)
BLACK
+

+

+

+

+

+

+

+

+
20
11
10
1
60
51
50
40
21
41
T20 18LB
T19 18WT
T16 18RD
T16 18RD
T15 18LG
T14 18LG/WT
T13 18DB/BK
K22 18OR/DB
F11 18RD/WT
T10 18YL/DG
T9 18OR/BK
F45 18YL/RD
D21 18PK
K24 18GY/BK
D2 18WT/BK
T3 18VT
T1 18LG/BK
40
39
38
37
36
35
34
33
32
31
30
29
28
27
26
25
24
23
22
21
20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
CAV
LOW/REVERSE SOLENOID CONTROL
2-4 SOLENOID CONTROL
12 VOLT SUPPLY
OUTPUT SHAFT SPEED SENSOR SIGNAL
SPEED SENSOR GROUND
THROTTLE POSITION SENSOR SIGNAL
TORQUE MANAGEMENT REQUEST SENSE
OVERDRIVE PRESSURE SWITCH SENSE
FUSED IGNITION (ST)
SCI TRANSMIT
CCD BUS(-)
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
CIRCUIT
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
FUNCTION
NSGS8085 J988W-3

(CONTINUED)
T60 18BR
T59 18PK
G7 18WT/OR
Z13 16BK/RD
A5 18RD/DB
T54 18VT/LG
Z14 16BK/YL
T52 18RD/BK
K4 18BK/LB
T50 18DG
T47 18YL/BK
D6 18PK/LB
D1 18VT/BR
T42 18VT/WT
T41 18BK/WT
60
59
58
57
56
55
54
53
52
51
50
49
48
47
46
45
44
43
42
41
CAV
OVERDRIVE SOLENOID CONTROL
UNDERDRIVE SOLENOID CONTROL
EATX GROUND
FUSED B(+)
EATX GROUND
INPUT SPEED SENSOR SIGNAL
SENSOR GROUND
LOW/REVERSE PRESSURE SWITCH SENSE
2/4 PRESSURE SWITCH SENSE
SCI RECEIVE
CCD BUS(+)
-
-
-
-
-
CIRCUIT
-
-
-
-
-
FUNCTION
RANGE SENSOR
TRANSMISSION
5
10 6
1
BLACK
T41 18BR/YL
T42 18VT/WT
T3 18VT
T1 18LG/BK
L1 18VT/BK
T41 18BK/WT
T54 18VT/LG
T13 18DB/BK
F20 18WT
10
9
8
7
6
5
4
3
2
1
CAV
TRANSMISSION RANGE SENSOR T41 SENSE
BACK-UP LAMP FEED
TRANSMISSION TEMPERATURE SENSOR SIGNAL
SPEED SENSOR GROUND
-
CIRCUIT
-
FUNCTION
5 6 3 4
8 7 2 1
BLACK
T19 18WT
T20 18LB
T60 18BR
T59 18PK
T16 18RD
T9 18OR/BK
T50 18DG
T47 18YL/BK
8
7
6
5
4
3
2
1
CAV
2/4 SOLENOID CONTROL
LOW/REVERSE SOLENOID CONTROL
OVERDRIVE SOLENOID CONTROL
UNDERDRIVE PRESSURE SWITCH SENSE
OVERDRIVE PRESSURE SWITCH SENSE
LOW/REVERSE PRESSURE SWITCH SENSE
2/4 PRESSURE SWITCH SENSE
CIRCUIT FUNCTION
TRANSMISSION
CONTROL SOLENOIDS
TRANSMISSION TEMPERATURE SENSOR SIGNAL
J988W-3 NSGS8086

CONTROL SERVO
VEHICLE SPEED
4 1
BLACK
Z1 18BK
V30 18DB/RD
V35 18LG/RD
V36 18TN/RD
4
3
2
1
CAV
GROUND
SPEED CONTROL VENT SOLENOID CONTROL
SPEED CONTROL VACUM SOLENOID CONTROL
CIRCUIT FUNCTION
OXYGEN SENSOR
UPSTREAM HEATED
4 3
2
K41 18BK/DG
K4 18BK/LB
A142 18DG/OR
Z1 18BK
4
3
2
1
CAV
UPSTREAM HEATED OXYGEN SENSOR SIGNAL
SENSOR GROUND
ASD RELAY OUTPUT
GROUND
CIRCUIT FUNCTION
GRAY
1
BOOST PRESSURE SIGNAL K1 18DG/RD 4
4 1
TURBO BOOST
PRESSURE SENSOR
(DIESEL)
K9 18LB 3
K21 18BK/RD INTAKE AIR TEMPERATURE SIGNAL
SENSOR GROUND K4 18BK/LB
2
1
FUNCTION CIRCUIT
SPEED SENSOR GROUND
INPUT SPEED SENSOR SIGNAL
CAV
1
2
T13 18DB/BK
T52 18RD/BK
GRAY
1 2
TURBINE
SPEED SENSOR
5 VOLT SUPPLY
NSGS8087 J988W-3

MODULE
WIPER
- -
- -
- -
- -
BLACK
GROUND
WIPER HIGH/LOW RELAY HIGH SPEED OUTPUT
WIPER PARK SWITCH SENSE
WIPER HIGH/LOW RELAY LOW SPEED OUTPUT
10
5
6
1
Z1 14BK
V4 12RD/YL
V7 20DG/WT
V3 12BR/WT
10
9
8
7
6
5
4
3
2
1
CAV
-
-
CIRCUIT
-
-
FUNCTION
11 4
GROUND Z1 14BK
(BUILT-UP-EXPORT)
MODULE
WIPER
1 V3 12BR/WT WIPER HIGH/LOW RELAY LOW SPEED OUTPUT
2 V7 20DG/WT WIPER PARK SWITCH SENSE
3 V4 12RD/YL WIPER HIGH/LOW RELAY HIGH SPEED OUTPUT
4
(EXCEPT 3.3L/3.8L)
SENSOR
VEHICLE SPEED
3
2
8 VOLT SUPPLY K7 18OR
G7 18WT/OR VEHICLE SPEED SENSOR SIGNAL
K4 20BK/LB* SENSOR GROUND
1
F87 18WT/BK* 1
K4 18BK/LB SENSOR GROUND 2
* DIESEL
BLACK
BLACK
1 3
J988W-3 NSGS8088
8W-90 CONNECTOR/GROUND LOCATIONS
INDEX
page page
CONNECTOR/GROUND LOCATIONS . . . . . . . . . . 1
CONNECTOR/GROUND LOCATIONS . . . . . . . . . 31
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . 1
INTRODUCTION
Thi s secti on provi des i l l ustrati ons i denti fyi ng the
general l ocati on of components, grounds, and connec-
tors i n the vehi cl e. A i ndex i s provi ded. Use the wi r-
i ng di agrams i n each secti on for connector/ground
number i denti fi cati on. Refer to the i ndex for the
proper fi gure number.
CONNECTOR/GROUND LOCATIONS
For i tems not shown i n thi s secti on a N/S i s pl aced
i n the Fi g. col umn.
Component/
Ground
Color Location Fig.
A/C
Compressor
Clutch
BK Top of A/C
Compressor
5, 6, 7,
8, 9
A/C-Heater
Control Module
C1
NAT Rear of Control 11
A/C-Heater
Control Module
C2
BK Rear of Control 11
A/C Pressure
Transducer
GY RT Side Cowl 3
A/C Zone Door
Actuator
NAT LT Side of
HVAC
15
Airbag Control
Module C1
YL Rear of I.P.
Center Stack
12
Airbag Contol
Module C2
BK Rear of I.P.
Center Stack
12
All Wheel Drive
Solenoid
BK Near Fuel Tank 20
Ambient
Temperature
Sensor
BK On Radiator
Closure Panel
4
Ash Receiver
Lamp
RD At Lamp 10
Automatic
Day/Night Mirror
BK At Mirror 15
B01 BK LT Kick Panel 18
B03 BK RT Kick Panel 18
Component/
Ground
Color Location Fig.
B09 BK Under Seat 16
B17 BK LT Quarter
Panel
21
B23 BK RT of Steering
Column
13
B33 BK LT Frame Rail 2
B56 RD Under Seat 16
B70 LT/GY LT Frame Rail 2
B75 BL Bottom of RT
B-Pillar
12
B98 BK Rear of RT Tail N/S
B99 BK Rear of LT Tail
Lamp
N/S
B120 BK LT Kick Panel N/S
Backup Lamp
Switch (M/T)
BK On
Transmission
5, 6, 8
Blend Door
Actuator
NAT LT Side of
HVAC
15
Body Control
Module C1
NAT On Junction
Block
12, 13
Brake Pressure
Switch
BK On Master
Cylinder
2
C19 Above RT
Vanity Mirror
17
Camshaft
Position Sensor
2.4L
BK Rear of
Cylinder Head
6, 7
NS/GS 8W - 90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 1
Component/
Ground
Color Location Fig.
Camshaft
Position Sensor
3.3L, 3.8L
BK RT Side of
Engine
9
Center Dome
Lamp
BK At Lamp N/S
CHMSL RD Rear of CHMSL 21
Cigar Lighter BK Rear of Lighter 9
Clockspring C1 YL Rear of
Clockspring
11
Clockspring C2 NAT Rear of
Clockspring
11
Clutch Interlock
Switch
BK Top of Clutch
Pedal
13
Controller
Anti-Lock Brake
BK RT Side of
Engine
Compartment
N/S
Crankcase Vent
Heater
At Heater N/S
Crankshaft
Position Sensor
BK Rear of Engine 5, 6, 7,
9
D01 BK On Kick Panel 18
Data Link
Connector
BK LT of Steering
Column
12
Downstream
Heated Oxygen
Sensor
BK Front Center of
Floor Pan
16
Driver Airbag YL Rear of Airbag 11
E36 BK LT Frame Rail 2
E40 BK At Radiator Fan
Module
N/S
E43 LT/GY LT Frame Rail 2
E69 BK LT Side of
Intake
6, 7
E78 BK Near Throttle
Body
9
EC1 Above RT
Vanity Mirror
17
EGR Solenoid BK LT Rear of
Engine
6, 9
Electric Wiper
De-Icer C1
BK At Left Base of
Windshield
11
Electric Wiper
De-Icer C2
BK At Right Base
of Windshield
11
Component/
Ground
Color Location Fig.
Engine Coolant
Temp Sensor
2.4L
BK On Cylinder
Block
N/S
Engine Coolant
Temp Sensor
2.5
BK On Cylinder
Head
8
Engine Coolant
Temp Sensor
3.3L, 3.8L
BK On Cylinder
Block
N/S
Engine Oil
Pressure Switch
GN On Cylinder
Block
5, 6, 7,
8, 9
Engine Starter
Motor
Rear of Starter 5, 6, 7,
8, 9
EVAP/Purge
Solenoid
BK RT Motor
Mount
3
Evaporator
Temperature
Sensor
BK RT Side of
HVAC
N/S
F02 BK Near Throttle
Body
9
F09 BK LT Side of
Intake
6, 7
Front Blower
Motor
BK At Motor 10
Front Blower
Motor Resistor
Block
BK RT Side Cowl 4
Front Cigar
Lighter
BK Rear of Lighter 9
Front Reading
Lamps/Switch
RD At Lamp 15
Front Washer
Motor
BK Bottom of
Reservior
4
Fuel Injection
Pump
BK Near Pump 8
Fuel Injector #1 BK At Injector N/S
Fuel Injector #5 BK At injector N/S
Fuel Injectors
(2.0L)
BK At Injectors 5
Fuel Pump
Heater
BK At Heater N/S
Fuel Pump
Module
LT/GY Side of Fuel
Tank
20
8W - 90 - 2 8W - 90 CONNECTOR/GROUND LOCATIONS NS/GS
Component/
Ground
Color Location Fig.
G100 LT Frame Rail 3
G101 2.4L Rear of
Cylinder Head
6, 7
G101 3.3L, 3.8L Rear of
Cylinder Block
9
G103 2.4L Rear of
Cylinder Head
6, 7
G103 3.3L, 3.8L Rear of
Cylinder Block
9
G104 Rear of Right
Headlamp
4
G200 Right of I.P.
Center Stack
10
G201 I.P. Center
Support
10
G202 I.P. Center
Support
10
G204 I.P. Center
Support
10
G300 LT Kick Panel 13
G301 RT Kick Panel 14
G302 LT Quarter
Panel
21
G400 In Liftgate 23
Generator BK Rear of
Generator
5, 6, 7,
8, 9
Glove Box
Lamp
BL Rear of Glove
Box
11
Glow #1 BK At Glow Plug 8
Headlamp
Dimmer Switch
BK Part of
Multifunction
Switch
11
Headlamp
Switch C1
NAT Rear of Switch 11
Headlamp
Switch C2
BK Rear of Switch 11
Headlamp
Washer Pump
BK At Pump N/S
High Note Horn BK LT Frame Rail 4
Hood Ajar
Switch
NAT LT Fender 2
Component/
Ground
Color Location Fig.
Horn Switch Rear of Driver
Airbag
11
Idle Air Control
Motor
BK On Throttle
Body
5, 6, 7,
8, 9
Ignition Coil
Pack 2.0L
BK Top of Valve
Cover
5
Ignition Coil
Pack 2.4L
BK Top of Valve
Cover
6, 7
Ignition Coil
Pack 3.3L, 3.8L
BK RT Side of
Engine
9
Ignition Switch
C1
GY Rear of Switch 11
Ignition Switch
C2
GN Rear of Switch 11
Ignition Switch
C3
Instrument
Cluster
RD Rear of Cluster 11
Intake Air Temp
Sensor
GY On Intake 6, 7
J01D BK RT Side of
HVAC
15
J02A BK Top of Liftgate 23
JO3A BK Top of Liftgate 23
Junction Block
C1
GY On Junction
Block
13
Junction Block
C2
GY On Junction
Block
13
Junction Block
C3
GY On Junction
Block
12
Junction Block
C4
GY On Junction
Block
12
Key-In Halo
Lamp
WT Rear of Lamp 11
Knock Sensor
2.0L
GY Front of
Cylinder Block
5
Knock Sensor
2.4L
GY Front of
Cylinder Block
6, 7
Knock Sensor
3.3L, 3.8L
GY Front of
Cylinder Block
N/S
L15 BK Top of Liftgate 23
Left Flasher
Relay
BK LT Rear
Quarter Panel
N/S
Left Door Ajar
Switch
BK LT B-PIllar 14
Component/
Ground
Color Location Fig.
Left Door
Arm/Disarm
Switch
BK At Switch 19
Left Door
Courtesy Lamp
BK At Lamp 19
Left Door
Speaker
BK At Speaker 19
Left Front Fog
Lamp
BK At Lamp 4
Left Front Door
Lock Motor
BK At Motor 19
Left Front Panel
Speaker
BK At Speaker 11
Left Front
Park/Turn
Signal Lamp
BK At Lamp 4
Left Front
Wheel Speed
Sensor
BK LT Fender Side
Shield
2
Left Front
Window Motor
RD At Motor 19
Left Headlamp BK At Lamp 2
Left Headlamp
Leveling Motor
BK At Motor N/S
Left Liftgate
Flood Lamp
BK At Lamp 21
Left Mid
Reading Lamp
GY At Lamp 15
Left Power Door
Lock Switch
BK At Switch 19
Left Power
Mirror C1
RD At Mirror 11
Left Power
Mirror C2
BL At Mirror 11
Left Power
Window Switch
BK At Switch 19
Left Rear Door
Ajar Switch
BK LT C-Pillar 21
Left Rear Lamp
Assembly
BK At Lamp 21
Left Rear Pillar
Speaker
BK At Speaker 21
Left Rear
Reading Lamp
BK At Lamp 15
Left Rear
Sliding Door
Contacts
BK LT B-Pillar 14
Component/
Ground
Color Location Fig.
Left Rear
Sliding Door
Lock Motor
BK At Motor N/S
Left Rear
Speaker
BK At Speaker 21
Left Rear Vent
Motor
NAT At Motor 21
Left Rear Wheel
Speed Sensor
BK Center Rear of
Floor Pan
16
Left Repeater
Lamp
GY At Lamp N/S
Left Speed
Control Switch
Left Side of
Steering Wheel
Pad
11
Left Stop/Turn
Signal Relay
BK LT Quarter
Panel
N/S
Left Visor/Vanity
Lamp
BK At Lamp 15
License Lamp GY At Lamps 21
Liftgate Ajar
Switch
BK At Latch 21
Liftgate
Arm/Disarm
Switch
BK At Key Cylinder 21
Liftgate Door
Lock Motor
BK At Motor 21
LJ01 BK LT Quarter
Panel
21
Low Coolant
Switch
BK At Reservior 8
Low Note Horn BK LT Frame Rail 4
Low Washer
Fluid Level
Switch
BK Bottom of
Reservior
N/S
MAP Sensor
2.0L
BK On Intake 5
MAP Sensor
2.4L
BK On Intake N/S
MAP Sensor
3.3L, 3.8L
BK Near Throttle
Body
9
Memory
Seat/Mirror
Module
BK Under Seat 16
Memory Set
Switch
BL At Switch 19
Component/
Ground
Color Location Fig.
Message Center BL Rear of
Message
Center
11
Mode Door
Actuator
BK LT Side of
HVAC
15
Multi Function
Switch
Name Brand
Speaker Relay
LT/GY LT of Steering
Column
11
Needle
Movement
Sensor
BK Back of
Generator
8
Output Shaft
Speed Sensor
GY Front of
Transmission
7, 9
Overhead
Console
RD Front of
Console
15
P18 GY RT of Steering
Column
12
P25 BK RT of I.P
Center Stack
10
P30 BK RT Side of
HVAC
10
Column
12
P50 NAT Right Side of
HVAC Unit
Taped to
Harness
10
Park Brake
Switch
BK Top of Park
Brake
13
Park/Neutral
Positon Switch
BK Front of
Transmission
N/S
Passenger
Airbag
YL Rear of Airbag 11
PDC C1 NAT Bottom of PDC 2
PDC C2 OR Bottom of PDC 2
PDC C3 DK/
GN
Bottom of PDC 2
PDC C4 BK Bottom of PDC 2
PDC C5 LT/GY Bottom of PDC 2
PDC C6 LT/GN Bottom of PDC 3
PDC C8 BL Bottom of PDC 3
Power Folding
Mirror Switch
BK At Switch N/S
Component/
Ground
Color Location Fig.
Power Mirror
Switch
Power Steering
Pressure Switch
BK RT Side of
Engine
Compartment
N/S
Powertrain
Control Module
C1
BK LT Fender Side
Shield
3
Powertrain
Control Module
C2
BK LT Fender Side
Shield
3
Radiator Fan
No.1
BK At Motor N/S
Radiator Fan
No.2
BK At Motor N/S
Radiator Fan
Solid State
Relay
BK LT Front Frame
Rail
3
Radio C1 GY Rear of Radio 11
Radio C2 BK Rear of Radio 11
Radio Choke LT/GY Rear of Radio N/S
Rear A/C-
Heater Unit
LT/GN RT Quarter
Panel
22
Rear Blower
Front Control
Switch
Rear Blower
Rear Control
Switch
BK At Switch N/S
Rear Cigar
Lighter/Power
Outlet
BK LT Quarter
Panel
21
Rear Dome
Lamp
BK At Lamp N/S
Rear Washer
Motor
BK Bottom of
Reservior
4
Rear Window
Defogger
BK On Liftgate 21
Rear Wiper
Motor
BK At Motor 21
Recirculation
Door Actuator
NAT RT Side of
HVAC
15
Remote Keyless
Entry Module
RD Top Left of I.P. 11
RF3 BK At Radiator Fan N/S
Component/
Ground
Color Location Fig.
Right Door
Arm/Disarm
Switch
BK At Switch 17
Right Door
Courtesy Lamp
BK At Lamp 17
Right Door
Speaker
BK At Speaker 17
Right Flasher
Relay
BK LT Quarter
Panel
N/S
Right Front Fog
Lamp
BK At Lamp 4
Right Front
Door Ajar
Switch
BK RT B-Pillar 12
Right Front
Door Lock
Motor
BK At Motor 17
Right Front
Panel Speaker
BK At Speaker 11
Right Front
Park/Turn
Signal Lamp
BK At Lamp 4
Right Front
Wheel Speed
Sensor
BK Right Fender
Side Shield
4
Right Front
Window Motor
RD At Motor 19
Right Headlamp BK At Lamp 4
Right Headlamp
Leveling Motor
BK At Motor N/S
Right Liftgate
Flood Lamp
BK At Lamp 23
Right Mid
Reading Lamp
GY At Lamp 17
Right Power
Door Lock
Switch
BK At Switch 19
Right Power
Mirror C1
RD At Mirror 11
Right Power
Mirror C2
BL At Mirror 11
Right Power
Window Switch
BK At Switch 19
Right Rear
Lamp Assembly
BK At Lamp 22
Right Rear Door
Ajar Switch
BK RT C-Pillar 22
Component/
Ground
Color Location Fig.
Right Rear Pillar
Speaker
BK At Speaker 22
Right Rear
Reading Lamp
GY At Lamp 17
Right Rear
Sliding Door
Contact
BK RT B-Pillar 14
Right Rear
Sliding Door
Lock Motor
BK At Motor N/S
Right Rear
Speaker
BK At Speaker 22
Right Rear Vent
Motor
NAT At Motor 22
Right Rear
Wheel Speed
Sensor
BK Center Rear of
Floor Pan
16
Right Repeater
Lamp
GY At Lamp N/S
Right Speed
Control Switch
Right Side of
Steering Wheel
Pad
11
Right Stop/Turn
Signal Relay
BK LT Quarter
Panel
N/S
Right Visor/
Vanity Lamp
BK At Lamp 17
S02 BK Under Seat N/S
Seat Belt Switch BK LT B-Pillar N/S
Sentry Key
Immobilizer
Module
BK Near Steering
at Module
11
Stop Lamp
Switch
GY Top of Brake
Pedal
13
T05 BK LT Quarter
Panel
N/S
T08 BK LT Quarter
Panel
N/S
Throttle Position
Sensor
NAT On Throttle
Body
5, 6, 7,
8, 9
Trailer Tow
Connector
BK LT Quarter
Panel
N/S
Transmission
Control Module
BK RT Fender Side
Shield
3
Transmission
Range Sensor
BK Top of
Transmission
7, 9
Component/
Ground
Color Location Fig.
Transmission
Control
Solenoids
BK Front of
Transmission
7, 9
Turbine Speed
Sensor
GY Front of
Transmission
7, 9
Turn Signal/
Hazard Switch
BK Part of
Multifunction
Switch
11
Upstream
Heated Oxygen
Sensor
GY Rear of Engine 5, 6, 7,
8, 9
Component/
Ground
Color Location Fig.
Vehicle Speed
Control Servo
BK LT Rear of
Engine
Compartment
5, 6, 7,
8, 9
Vehicle Speed
Sensor
BK Rear of
Transmission
5, 6, 8
Windshield
Wiper Switch
BK Part of
Multifunction
Switch
11
Wiper Module BK LT Side of
Engine
2
F
i
g
.
1
G
r
o
u
n
d
L
o
c
a
t
i
o
n
s
L
H
D
F
i
g
.
2
E
n
g
i
n
e
C
o
m
p
a
r
t
m
e
n
t
C
o
n
n
e
t
i
o
n
s
L
H
D
F
i
g
.
3
E
n
g
i
n
e
C
o
m
p
a
r
t
m
e
n
t
C
o
n
n
e
c
t
i
o
n
s
L
H
D
F
i
g
.
4
E
n
g
i
n
e
C
o
m
p
a
r
t
m
e
n
t
C
o
n
n
e
c
t
i
o
n
s
L
H
D
F
i
g
.
5
E
n
g
i
n
e
C
o
n
n
e
c
t
i
o
n
s
2
.
0
L
,
L
H
D
F
i
g
.
6
E
n
g
i
n
e
C
o
n
n
e
c
t
i
o
n
s
2
.
4
L
(
M
/
T
)
,
L
H
D
F
i
g
.
7
E
n
g
i
n
e
C
o
n
n
e
c
t
i
o
n
s
2
.
4
L
(
A
/
T
)
,
L
H
D
F
i
g
.
8
E
n
g
i
n
e
C
o
n
n
e
c
t
i
o
n
s
2
.
5
L
,
L
H
D
F
i
g
.
9
E
n
g
i
n
e
C
o
n
n
e
c
t
i
o
n
s
3
.
3
L
,
3
.
8
L
,
L
H
D
F
i
g
.
1
0
I
n
s
t
r
u
m
e
n
t
P
a
n
e
l
C
o
n
n
e
c
t
i
o
n
s
L
H
D
F
i
g
.
1
1
I
n
s
t
r
u
m
e
n
t
P
a
n
e
l
C
o
n
n
e
c
t
i
o
n
s
L
H
D
F
i
g
.
1
2
I
n
s
t
r
u
m
e
n
t
P
a
n
e
l
C
o
n
n
e
c
t
i
o
n
s
L
H
D
F
i
g
.
1
3
C
o
w
l
P
a
n
e
l
C
o
n
n
e
c
t
i
o
n
s
L
H
D
F
i
g
.
1
4
B
o
d
y
C
o
n
n
e
c
t
i
o
n
s
L
H
D
F
i
g
.
1
5
H
V
A
C
C
o
n
n
e
c
t
i
o
n
s
L
H
D
F
i
g
.
1
6
B
o
d
y
C
o
n
n
e
c
t
i
o
n
s
L
H
D
F
i
g
.
1
7
R
o
o
f
P
a
n
e
l
C
o
n
n
e
c
t
i
o
n
s
L
H
D
F
i
g
.
1
8
B
o
d
y
t
o
D
o
o
r
C
o
n
n
e
c
t
i
o
n
s
L
H
D
F
i
g
.
1
9
D
o
o
r
C
o
n
n
e
c
t
i
o
n
s
L
H
D
F
i
g
.
2
0
U
n
d
e
r
b
o
d
y
C
o
n
n
e
c
t
i
o
n
s
L
H
D
F
i
g
.
2
1
L
e
f
t
R
e
a
r
Q
u
a
r
t
e
r
C
o
n
n
e
c
t
i
o
n
s
L
H
D
F
i
g
.
2
2
R
i
g
h
t
R
e
a
r
Q
u
a
r
t
e
r
C
o
n
n
e
c
t
i
o
n
s
L
H
D
F
i
g
.
2
3
L
i
f
t
g
a
t
e
C
o
n
n
e
c
t
i
o
n
s
L
H
D
CONNECTOR/GROUND LOCATIONS
For i tems not shown i n thi s secti on a N/S i s pl aced
i n the Fi g. col umn.
Component/
Ground
Color Location Fig.
A/C
Compressor
Clutch
BK Top of A/C
Compressor
5, 6, 7,
8, 9
A/C-Heater
Control Module
C1
NAT Rear of Control 11
A/C-Heater
Control Module
C2
BK Rear of Control 11
A/C Pressure
Transducer
GY RT Side Cowl 3
A/C Zone Door
Actuator
NAT LT Side of
HVAC
15
Airbag Control
Module C1
YL Rear of I.P.
Center Stack
12
Airbag Contol
Module C2
BK Rear of I.P.
Center Stack
12
All Wheel Drive
Solenoid
BK Near Fuel Tank 20
Ambient
Temperature
Sensor
GY On Radiator
Closure Panel
4
Ash Receiver
Lamp
RD At Lamp 10
Automatic
Day/Night Mirror
BK At Mirror 17
B17 BK LT Quarter
Panel
21
B23 BK RT of Steering
Column
13
B33 BK LT Frame Rail 2
B70 LT/GY LT Frame Rail 2
B75 BL Bottom of RT
B-Pillar
14
B98 BK Rear of RT Tail
Lamp
N/S
Component/
Ground
Color Location Fig.
B99 BK Rear of LT Tail
Lamp
N/S
B120 BK LT Kick Panel N/S
Backup Lamp
Switch (M/T)
BK On
Transmission
5, 6, 8
Blend Door
Actuator
NAT LT Side of
HVAC
15
Body Control
Module C1
NAT On Junction
Block
12
Body Control
Module C2
NAT On Junction
Block
12
Brake Pressure
Switch
BK On Master
Cylinder
2
C19 At Top Center
of Windshield
17
C20 Bottom of RT
B-Pillar
N/S
Camshaft
Position Sensor
2.4L
BK Rear of
Cylinder Head
6, 7
Camshaft
Position Sensor
3.3L, 3.8L
BK RT Side of
Engine
9
Center Dome
Lamp
BK At Lamp N/S
CHMSL RD Rear of CHMSL 23
Clockspring C1 YL Rear of
Clockspring
11
Clockspring C2 NAT Rear of
Clockspring
11
Clutch Switch BK Top of Clutch
Pedal
13
Controller
Anti-Lock Brake
BK LT Side of
Engine
Compartment
N/S
Crankshaft
Position Sensor
BK Rear of Engine 5, 6, 7,
9
Data Link
Connector
BK LT of Steering
Column
12
Component/
Ground
Color Location Fig.
Downstream
Heated Oxygen
Sensor
BK Front Center of
Floor Pan
16
Driver Airbag YL Rear of Airbag 11
E36 BK LT Frame Rail 2
E40 BK At Radiator Fan
Module
N/S
E43 LT/GY LT Frame Rail 2
E69 BK LT Side of
Intake
6, 7
E78 BK Near Throttle
Body
9
EC1 At Top Center
of Windshield
17
EGR Solenoid BK LT Rear of
Engine
6, 9
Electric Wiper
De-Icer C1
BK At Right Base
of Windshield
11
Electric Wiper
De-Icer C2
BK At Left Base of
Windshield
11
Engine Coolant
Temp Sensor
2.4L
BK On Cylinder
Block
N/S
Engine Coolant
Temp Sensor
3.3L, 3.8L
BK On Cylinder
Block
N/S
Engine Oil
Pressure Switch
GN On Cylinder
Block
5, 6, 7,
8, 9
Engine Starter
Motor
Rear of Starter 5, 6, 7,
8, 9
EVAP/Purge
Solenoid
BK RT Motor
Mount
3
Evaporator
Temperature
Sensor
BK RT Side of
HVAC
N/S
F02 BK Near Throttle
Body
9
F09 BK LT Side of
Intake
6, 7
Front Blower
Motor
BK At Motor 10
Front Blower
Motor Resistor
Block
BK LT Side of
Engine
2
Front Cigar
Lighter
BK Rear of Lighter 11
Component/
Ground
Color Location Fig.
Front Reading
Lamps/Switch
BL At Lamp 17
Front Washer
Motor
BK Bottom of
Reservior
4
Fuel Pump
Module
GY Side of Fuel
Tank
20
G101 2.4L Rear of
Cylinder Head
6, 7
G101 3.3L, 3.8L Rear of
Cylinder Block
9
G103 2.4L Rear of
Cylinder Head
6, 7
G103 3.3L, 3.8L Rear of
Cylinder Block
9
G104 Near T/O for
RT Headlamp
N/S
G200 Left of I.P.
Center Stack
10
G201 I.P. Center
Support
10
G202 I.P. Center
Support
10
G204 I.P. Center
Support
10
G300 BK LT Kick Panel 13
G301 RT Kick Panel 13, 14
G302 BK LT Quarter
Panel
21
G400 BK In Liftgate 23
Generator BK Rear of
Generator
5, 6, 7,
8, 9
Glove Box
Lamp
BL Rear of Glove
Box
11
Headlamp
Dimmer Switch
BK Part of
Multifunction
Switch
11
Component/
Ground
Color Location Fig.
Headlamp
Switch C1
NAT Rear of Switch 11
Headlamp
Switch C2
Headlamp
Washer Motor
Bottom of
Reservior
N/S
High Note Horn BK LT Frame Rail 4
Hood Ajar
Switch
NAT LT Fender 2
Horn Switch Rear of Driver
Airbag
11
Idle Air Control
Motor
BK On Throttle
Body
5, 6, 7,
8, 9
Ignition Coil
Pack 2.4L
BK Top of Valve
Cover
6, 7
Ignition Coil
Pack 3.3L, 3.8L
BK RT Side of
Engine
9
Ignition Switch
C1
GY Rear of Switch 11
Ignition Switch
C2
GN Rear of Switch 11
Ignition Switch
C3
Instrument
Cluster
RD Rear of Cluster 11
Intake Air Temp
Sensor
GY On Intake 6, 7
J01D BK RT Side of
HVAC
15
J02A BK Top of Liftgate 23
JO3A BK Top of Liftgate 23
Junction Block
C1
GY On Junction
Block
12, 13
Junction Block
C2
GY On Junction
Block
12, 13
Junction Block
C3
GY On Junction
Block
12
Junction Block
C4
GY On Junction
Block
12
Key-In Halo
Lamp
WT Rear of Lamp 11
Knock Sensor
2.4L
GY Front of
Cylinder Block
6, 7
Knock Sensor
3.3L, 3.8L
GY Front of
Cylinder Block
N/S
Component/
Ground
Color Location Fig.
Left
Combination
Relay
BK LT Rear
Quarter Panel
N/S
Left Door Ajar
Switch
BK LT B-PIllar 12
Left Door
Arm/Disarm
Switch
BK At Switch 19
Left Door
Courtesy Lamp
BK At Lamp 19
Left Door
Speaker
BK At Speaker 19
Left Fog Lamp GY At Lamp 4
Left Front Door
Lock Motor
BK At Motor 19
Left Front Panel
Speaker
BK At Speaker 11
Left Front
Park/Turn
Signal Lamp
BK At Lamp 4
Left Front
Wheel Speed
Sensor
BK LT Fender Side
Shield
2
Left Front
Window Motor
RD At Motor 19
Left Headlamp BK At Lamp 2
Left Headlamp
Leveling Motor
BK At Motor N/S
Left Liftgate
Flood Lamp
BK At Lamp 23
Left Mid
Reading Lamp
GY At Lamp 17
Left Power Door
Lock Switch
BK At Switch 19
Left Power
Mirror C1
RD At Mirror 11
Left Power
Mirror C2
BL At Mirror 11
Left Power
Window Switch
OR At Switch 19
Left Rear Lamp
Assembly
BK At Lamp 21
Left Rear Door
Ajar Switch
BK LT C-Pillar 21
Left Rear Pillar
Speaker
BK At Speaker 21
Component/
Ground
Color Location Fig.
Left Rear
Reading Lamp
GY At Lamp 17
Left Rear
Sliding Door
Contact
BK LT B-Pillar 14
Left Rear
Sliding Door
Lock Motor
BK At Motor N/S
Left Rear
Speaker
BK At Speaker 21
Left Rear Vent
Motor
NAT At Motor 21
Left Rear Wheel
Speed Sensor
GY Center Rear of
Floor Pan
16
Left Repeater
Lamp
GY At Lamp N/S
Left Speed
Control Switch
Left Side of
Steering Wheel
Pad
11
Left Stop/Turn
Signal Relay
BK LT Quarter
Panel
N/S
Left Visor/Vanity
Lamp
BK At Lamp 17
License Lamp GY At Lamps 23
Liftgate Ajar
Switch
BK At Latch 23
Liftgate
Arm/Disarm
Switch
GY At Key Cylinder 23
Liftgate Lock
Motor
BK At Motor 23
LJ01 BK LT Quarter
Panel
21
Low Note Horn BK LT Frame Rail 4
Low Washer
Fluid Level
Sensor
BK Bottom of
Reservior
4
MAP Sensor
2.4L
BK On Intake N/S
MAP Sensor
3.3L, 3.8L
BK Near Throttle
Body
9
Memort
Seat/Mirror
Module
BK RT Front of
Floor Pan
16
Memory Set
Switch
BL At Switch 19
Component/
Ground
Color Location Fig.
Message Center BL Rear of
Message
Center
11
Mode Door
Actuator
BK LT Side of
HVAC
15
Multi Function
Switch
Name Brand
Speaker Relay
LT/GY LT of Steering
Column
N/S
Output Shaft
Speed Sensor
GY Front of
Transmission
7, 9
Overhead
Console
RD Front of
Console
17
Column
12
P30 BK RT Side of
HVAC
10
Column
12
P50 NAT Right Side of
HVAC Taped to
Harness
10
Park Brake
Switch
NAT Top of Park
Brake
N/S
Park/Neutral
Positon Switch
BK Front of
Transmission
N/S
Passenger
Airbag
YL Rear of Airbag 11
PDC C1 NAT Bottom of PDC 2
PDC C2 OR Bottom of PDC 2
PDC C3 DK/
GN
Bottom of PDC 2
PDC C4 BK Bottom of PDC 2
PDC C6 LT/GN Bottom of PDC 3
PDC C8 BL Bottom of PDC 3
Power Folding
Mirror Switch
BK At Switch N/S
Power Mirror
Switch
Power Steering
Pressure Switch
BK RT Side of
Engine
Compartment
N/S
Component/
Ground
Color Location Fig.
Powertrain
Control Module
C1
BK LT Fender Side
Shield
3
Powertrain
Control Module
C2
BK LT Fender Side
Shield
3
Radiator Fan
No.1
BK At Motor N/S
Radiator Fan
No.2
BK At Motor N/S
Radiator Fan
Relay
BK LT Front Frame
Rail
3
Radio C1 GY Rear of Radio 11
Radio Choke LT/GY Rear of Radio N/S
Rear A/C-
Heater Unit
LT/GN RT Quarter
Panel
22
Rear Blower
Front Control
Switch
Rear Blower
Rear Control
Switch
BK At Switch N/S
Rear Cigar
Lighter/Power
Outlet
BK LT Quarter
Panel
21
Rear Dome
Lamp
BK At Lamp N/S
Rear Washer
Motor
BK Bottom of
Reservior
4
Rear Window
Defogger
BK On Liftgate 23
Rear Wiper
Motor
BK At Motor 23
Recirculation
Door Actuator
NAT RT Side of
HVAC
15
Remote Keyless
Entry Module
RD Top RT of I.P. 11
Right
Combination
Relay
BK LT Quarter
Panel
N/S
Right Door
Arm/Disarm
Switch
BK At Switch 19
Right Door
Courtesy Lamp
BK At Lamp 19
Component/
Ground
Color Location Fig.
Right Door
Speaker
BK At Speaker 19
RF3 BK At Radiator Fan
Module
N/S
Right Fog Lamp GY At Lamp 4
Right Front
Door Ajar
Switch
BK RT B-Pillar 12
Right Front
Door Lock
Motor
BK At Motor 19
Right Front
Panel Speaker
BK At Speaker 11
Right Front
Park/Turn
Signal Lamp
BK At Lamp 4
Right Front
Wheel Speed
Sensor
BK Right Fender
Side Shield
4
Right Front
Window Motor
RD At Motor 19
Right Headlamp BK At Lamp 4
Right Headlamp
Leveling Motor
BK At Motor N/S
Right Liftgate
Flood Lamp
BK At Lamp 23
Right Mid
Reading Lamp
GY At Lamp 17
Right Power
Door Lock
Switch
BK At Switch 19
Right Power
Mirror C1
RD At Mirror 11
Right Power
Mirror C2
BL At Mirror 11
Right Power
Window Switch
BK At Switch 19
Right Rear
Lamp Assembly
BK At Lamp 22
Right Rear Door
Ajar Switch
BK RT C-Pillar N/S
Right Rear Pillar
Speaker
BK At Speaker 22
Right Rear
Reading Lamp
GY At Lamp 17
Component/
Ground
Color Location Fig.
Right Rear
Sliding Door
Contact
BK RT B-Pillar 14
Right Rear
Sliding Door
Lock Motor
BK At Motor N/S
Right Rear
Speaker
BK At Speaker 22
Right Rear Vent
Motor
NAT At Motor 22
Right Rear
Wheel Speed
Sensor
GY Center Rear of
Floor Pan
16
Right Repeater
Lamp
GY At Lamp N/S
Right Speed
Control Switch
Right Side of
Steering Wheel
Pad
11
Right Stop/Turn
Signal Relay
BK LT Quarter
Panel
N/S
Right Visor/
Vanity Lamp
BK At Lamp 17
S02 BK Under Seat N/S
Seat Belt Switch BK RT B-Pillar N/S
Sentry Key
Immobilizer
Module
BK Near Steering
Column at
Module
11
Stop Lamp
Switch
GY Top of Brake
Pedal
12
T05 BK LT Quarter
Panel
N/S
T08 BK RT Quarter
Panel
N/S
Component/
Ground
Color Location Fig.
Throttle Position
Sensor
NAT On Throttle
Body
5, 6, 7,
8, 9
Trailer Tow
Connector
BK LT Quarter
Panel
N/S
Transmission
Control Module
BK RT Fender Side
Shield
3
Transmission
Range Sensor
BK Top of
Transmission
7. 9
Transmission
Control
Solenoids
BK Front of
Transmission
7, 9
Turbine Speed
Sensor
GY Front of
Transmission
7, 9
Turn Signal/
Hazard Switch
BK Part of
Multifunction
Switch
11
Upstream
Heated Oxygen
Sensor
GY Rear of Engine 5, 6, 7,
8, 9
Vehicle Speed
Control Servo
BK LT Rear of
Engine
Compartment
5, 6, 7,
8, 9
Vehicle Speed
Sensor
BK Rear of
Transmission
5, 6, 8
Windshield
Wiper Switch
BK Part of
Multifunction
Switch
11
Wiper Module BK LT Side of
Engine
2
F
i
g
.
1
G
r
o
u
n
d
L
o
c
a
t
i
o
n
s
R
H
D
F
i
g
.
2
E
n
g
i
n
e
C
o
m
p
a
r
t
m
e
n
t
C
o
n
n
e
t
i
o
n
s
R
H
D
F
i
g
.
3
E
n
g
i
n
e
C
o
m
p
a
r
t
m
e
n
t
C
o
n
n
e
c
t
i
o
n
s
R
H
D
F
i
g
.
4
E
n
g
i
n
e
C
o
m
p
a
r
t
m
e
n
t
C
o
n
n
e
c
t
i
o
n
s
R
H
D
F
i
g
.
5
E
n
g
i
n
e
C
o
n
n
e
c
t
i
o
n
s
2
.
0
L
,
R
H
D
F
i
g
.
6
E
n
g
i
n
e
C
o
n
n
e
c
t
i
o
n
s
2
.
4
L
(
M
/
T
)
,
R
H
D
F
i
g
.
7
E
n
g
i
n
e
C
o
n
n
e
c
t
i
o
n
s
2
.
4
L
(
A
/
T
)
,
R
H
D
F
i
g
.
8
E
n
g
i
n
e
C
o
n
n
e
c
t
i
o
n
s
2
.
5
L
,
R
H
D
F
i
g
.
9
E
n
g
i
n
e
C
o
n
n
e
c
t
i
o
n
s
3
.
3
L
,
3
.
8
L
,
R
H
D
F
i
g
.
1
0
I
n
s
t
r
u
m
e
n
t
P
a
n
e
l
C
o
n
n
e
c
t
i
o
n
s
R
H
D
F
i
g
.
1
1
I
n
s
t
r
u
m
e
n
t
P
a
n
e
l
C
o
n
n
e
c
t
i
o
n
s
R
H
D
F
i
g
.
1
2
I
n
s
t
r
u
m
e
n
t
P
a
n
e
l
C
o
n
n
e
c
t
i
o
n
s
R
H
D
F
i
g
.
1
3
C
o
w
l
P
a
n
e
l
C
o
n
n
e
c
t
i
o
n
s
R
H
D
F
i
g
.
1
4
B
o
d
y
C
o
n
n
e
c
t
i
o
n
s
R
H
D
F
i
g
.
1
5
H
V
A
C
C
o
n
n
e
c
t
i
o
n
s
R
H
D
F
i
g
.
1
6
B
o
d
y
C
o
n
n
e
c
t
i
o
n
s
R
H
D
F
i
g
.
1
7
R
o
o
f
P
a
n
e
l
C
o
n
n
e
c
t
i
o
n
s
R
H
D
F
i
g
.
1
8
B
o
d
y
t
o
D
o
o
r
C
o
n
n
e
c
t
i
o
n
s
R
H
D
F
i
g
.
1
9
D
o
o
r
C
o
n
n
e
c
t
i
o
n
s
R
H
D
F
i
g
.
2
0
U
n
d
e
r
b
o
d
y
C
o
n
n
e
c
t
i
o
n
s
R
H
D
F
i
g
.
2
1
L
e
f
t
R
e
a
r
Q
u
a
r
t
e
r
C
o
n
n
e
c
t
i
o
n
s
R
H
D
F
i
g
.
2
2
R
i
g
h
t
R
e
a
r
Q
u
a
r
t
e
r
C
o
n
n
e
c
t
i
o
n
s
R
H
D
F
i
g
.
2
3
L
i
f
t
g
a
t
e
C
o
n
n
e
c
t
i
o
n
s
R
H
D
8W-95 SPLICE LOCATIONS
INDEX
page page
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . 1
SPLICE LOCATION INDEX . . . . . . . . . . . . . . . . . . 1
SPLICE LOCATIONS (RHD) . . . . . . . . . . . . . . . . 15
INTRODUCTION
Thi s secti on provi des i l l ustrati ons i denti fyi ng the
general l ocati on of the spl i ces i n thi s vehi cl e. A spl i ce
i ndex i s provi ded. Use the wi ri ng di agrams i n each
secti on for spl i ce number i denti fi cati on. Refer to the
i ndex for the proper spl i ce number.
SPLICE LOCATION INDEX
Splice Number Location Fig.
BS01 Near Split for Tail Lamps 12
BS02 Near Fuel Tank T/O 12
BS03 Near Instrument Panel T/O 9
BS05 (2.5L) Near MSA Controller T/O N/S
BS06 (2.5L) Near MSA Controller T/O N/S
BS16 Near Right Park Lamp T/O 1
BS19 Near Horn T/O 1
BS30 (2.5L) Near Generator T/O 5
BS31 Near Left Headlamp Leveling
Motor T/O
1
BS31 (2.5L) In BCM T/O 5
BS32 (2.5L) In BCM T/O N/S
BS40 (2.5L) In Engine Harness T/O 5
BS41 (2.5L) In Engine Harness T/O N/S
CS01 Above Right Rear Door 11
CS03 Right B-Pillar 11
DS01 Near LT Power WDO T/O 10
ES01 In TCM T/O 7
ES01 (2.5L) Near Battery Positive Terminal
T/O
N/S
ES02 (2.0L) Near Camshaft Position
Sensor T/O
3
ES02 (2.4L) Near Fuel Rail T/O 4
ES02 (2.5L) Near Engine Speed Sensor
T/O
5
ES02
(3.3L,3.8L)
Near Transmission T/O 6
ES03 (2.0L) Near Distributor Coil T/O 2
ES03 (2.4L) Near PDC T/O 4
ES03
(3.3L,3.8L)
Near Body Ground T/O 7
ES05 (2.4L) Near Knock Sensor T/O 4
ES05 (2.5L) In Fuel Injection Pump T/O 5
ES05
(3.3L,3.8L)
ES06 (2.5L) Near Needle Movement
Sensor T/O
5
ES06
(3.3L,3.8L)
Near Transmission T/O N/S
ES07 (2.0L) Near Engine Ground T/O 2
ES07 (2.5L) Near Battery Negative
Terminal T/O
N/S
ES07 (2.4L) Near Body Ground T/O 4, 7
ES07
(3.3L,3.8L)
Near Battery Negative
Terminal T/O
6
ES08
(3.3L,3.8L)
ES09 (2.0L) In Battery Positive Terminal
T/O
7
ES09 (2.4L) Near Battery Positive Terminal 4
NS/GS 8W - 95 SPLICE LOCATIONS 8W - 95 - 1
T/O
N/S
ES09
(3.3L,3.8L)
In Battery Positive Terminal
T/O
7
ES10 Near Knock Sensor T/O 6
ES10
(3.3L,3.8L)
ES11 (2.0L) Near Battery Positive Terminal
T/O
7
Terminal T/O
4
ES11 (2.5L) In Generator T/O N/S
ES11
(3.3L,3.8L)
Terminal
7
ES12 (2.4L) Near Throttle Body T/O 4
Terminal T/O
N/S
ES12
(3.3L,3.8L)
Near Battery Positive Terminal
T/O
7
ES13 (2.4L) Near Generator T/O 4
ES13
(3.3L,3.8L)
Terminal T/O
7
ES14 (2.4L) Near Generator T/O 4,7
ES14
(3.3L,3.8L)
Terminal T/O
7
Sensor T/O
3
ES17
(3.3L,3.8L)
Terminal T/O
7
Sensor T/O
3
ES18
(3.3L,3.8L)
Near Engine Ground T/O 7
ES21 (2.0L) Near Body Ground T/O N/S
ES21
(3.3L,3.8L)
Near A/C Clutch T/O 6
ES23 (2.0L) Near Radiator Fan T/O N/S
ES23 (2.4L) Near Radiator Fan T/O 4
ES23
(3.3L,3.8L)
Near Engine ground T/O 7
ES24 (2.4L) Near Transmission T/O 4
ES24
(3.3L,3.8L)
T/O
N/S
T/O
N/S
ES29 (2.5L) Near Glow Plug Relay T/O N/S
ES30 (2.5L) Near Fuel Heater T/O 5
ES31 (2.5L) Near Fuel Heater T/O 5
ES37 (2.5L) Near Oil Pressure Switch T/O 5
ES40 (2.5L) Near Fuel Injection Pump T/O 5
FS01 (2.4L) Near ECT Sensor T/O N/S
FS01
(3.3L,3.8L)
Near Injector #5 T/O N/S
FS02 (2.4L) Near Inj #2 T/O N/S
FS02
(3.3L,3.8L)
Between Injs 4 and 6 N/S
FS03 (2.4L) Between Inj #2 and #3 N/S
PS01 Near Steering Column T/O 8
RFS01 Near Radiator Fan #2 N/S
8W - 95 - 2 8W - 95 SPLICE LOCATIONS NS/GS
F
i
g
.
1
F
r
o
n
t
E
n
d
S
p
l
i
c
e
s
L
H
D
F
i
g
.
2
E
n
g
i
n
e
S
p
l
i
c
e
s
2
.
0
L
,
L
H
D
F
i
g
.
3
E
n
g
i
n
e
S
p
l
i
c
e
s
2
.
0
L
,
L
H
D
F
i
g
.
4
E
n
g
i
n
e
S
p
l
i
c
e
s
2
.
4
L
,
L
H
D
F
i
g
.
5
E
n
g
i
n
e
S
p
l
i
c
e
s
2
.
5
L
,
L
H
D
F
i
g
.
6
E
n
g
i
n
e
S
p
l
i
c
e
s
3
.
3
L
,
3
.
8
L
,
L
H
D
F
i
g
.
7
E
n
g
i
n
e
C
o
m
p
a
r
t
m
e
n
t
S
p
l
i
c
e
s
3
.
3
L
,
3
.
8
L
,
L
H
D
F
i
g
.
8
I
n
s
t
r
u
m
e
n
t
P
a
n
e
l
S
p
l
i
c
e
s
L
H
D
F
i
g
.
9
C
o
w
l
P
a
n
e
l
S
p
l
i
c
e
s
L
H
D
F
i
g
.
1
0
L
e
f
t
D
o
o
r
S
p
l
i
c
e
L
H
D
F
i
g
.
1
1
D
o
m
e
H
a
r
n
e
s
s
S
p
l
i
c
e
s
L
H
D
F
i
g
.
1
2
F
l
o
o
r
P
a
n
a
n
d
U
n
d
e
r
b
o
d
y
S
p
l
i
c
e
s
L
H
D
SPLICE LOCATIONS (RHD)
BS02 Near Fuel Tank T/O 11
BS03 Near I/P Bulkhead
Connector T/O
8
BS05 Near Left Door T/O N/S
BS06 Near Left Door T/O N/S
BS08 Near Clutch Interlock switch
T/O
8
BS16 Near RT Park Lamp T/O 1
BS31 Near Left Headlamp
Leveling Motor T/O
1
DS01 Near LT Power WDO T/O 9
ES01 In TCM T/O 6
Sensor T/O
3
ES02 (2.4L) In Throttle Body T/O 4
ES02 (3.3L, 3.8L) Near Transmission T/O 5
ES03 (2.0L) Near Distributor Coil T/O 2
ES03 (2.4L) Near PDC T/O 4
ES03 (3.3L, 3.8L) Near Body Ground T/O 6
ES06 Near Transmission T/O N/S
ES07 (2.4L) Near Body Ground T/O 4
ES07 (3.3L, 3.8L) Near Battery Negative
Terminal T/O
6
ES08 (2.4L) Near Transmission T/O 4,6
ES09 (2.0L) Near Battery Positive
Terminal
N/S
Terminal
4
ES09 (3.3L, 3.8L) Near Battery Positive
Terminal
6
Terminal
N/S
Terminal T/O
4
Terminal
5,6
ES12 (2.4L) Near Throttle Body T/O 4
ES12 (3.3L, 3.8L) Near Battery Positive
Terminal T/O
6
ES13 (2.4L) Near Generator T/O 4
Terminal
4
ES14 (2.4L) Near Generator Field T/O 4
Terminal
4
Sensor T/O
3
ES17 (3.3L, 3,8L) Near Battery Negative
Terminal
4
Sensor T/O
3
ES18 (3.3L, 3.8L) Near Engine Ground T/O 6
ES21 (2.0L) Near Body Ground T/O N/S
ES21 (2.4L) Near Back Up Lamp Switch
T/O
4
ES21 (3.3L, 3.8L) Near A/C Clutch T/O 5
ES23 (2.0L) Near Radiator Fan T/O N/S
ES23 (2.4L) Near Radiator Fan T/O 4
ES23 (3.3L, 3.8L) Near Body Ground T/O 6
ES24 Near Transmission T/O 4,6
FS01 (2.4L) Near ECT Sensor T/O N/S
FS01 (3.3L, 3.8L) Near Injector #5 T/O N/S
FS02 (2.4L) Near Inj #2 T/O N/S
FS02 (3.3L, 3.8L) Between Injs 4 and 6 N/S
FS03 (2.4L) Between Inj #2 and #3 N/S
F
i
g
.
1
F
r
o
n
t
E
n
d
S
p
l
i
c
e
s
R
H
D
F
i
g
.
2
E
n
g
i
n
e
S
p
l
i
c
e
s
2
.
0
L
,
R
H
D
F
i
g
.
3
E
n
g
i
n
e
S
p
l
i
c
e
s
2
.
0
L
,
R
H
D
F
i
g
.
4
E
n
g
i
n
e
S
p
l
i
c
e
s
2
.
4
L
,
R
H
D
F
i
g
.
5
E
n
g
i
n
e
S
p
l
i
c
e
s
3
.
3
L
,
3
.
8
L
,
R
H
D
F
i
g
.
6
E
n
g
i
n
e
C
o
m
p
a
r
t
m
e
n
t
S
p
l
i
c
e
s
3
.
3
L
,
3
.
8
L
,
R
H
D
F
i
g
.
7
I
n
s
t
r
u
m
e
n
t
P
a
n
e
l
S
p
l
i
c
e
s
R
H
D
F
i
g
.
8
C
o
w
l
P
a
n
e
l
S
p
l
i
c
e
s
R
H
D
F
i
g
.
9
L
e
f
t
D
o
o
r
S
p
l
i
c
e
R
H
D
F
i
g
.
1
0
D
o
m
e
H
a
r
n
e
s
s
S
p
l
i
c
e
s
R
H
D
F
i
g
.
1
1
F
l
o
o
r
P
a
n
a
n
d
U
n
d
e
r
b
o
d
y
S
p
l
i
c
e
s
R
H
D
ENGINE
CONTENTS
page page
2. 4L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3. 0L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
3. 3/3. 8L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . 93
ENGINE DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . 7
STANDARD SERVICE PROCEDURES . . . . . . . . . . 1
STANDARD SERVICE PROCEDURES
INDEX
page page
GENERAL INFORMATION
CRANKSHAFT SPROCKET BOLT ACCESS
PLUG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
ENGINE CORE PLUGS . . . . . . . . . . . . . . . . . . . . 2
ENGINE OIL SERVICE . . . . . . . . . . . . . . . . . . . . . 5
ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
ENGINE PERFORMANCE . . . . . . . . . . . . . . . . . . 2
FORM-IN-PLACE GASKETS . . . . . . . . . . . . . . . . . 1
HONING CYLINDER BORES . . . . . . . . . . . . . . . . 3
HYDROSTATIC LOCKED ENGINE . . . . . . . . . . . . 5
MEASURING MAIN BEARING AND
CONNECTING ROD BEARING
CLEARANCES . . . . . . . . . . . . . . . . . . . . . . . . . 3
REPAIR OF DAMAGED OR WORN THREADS . . . 4
GENERAL INFORMATION
FORM-IN-PLACE GASKETS
There are numerous pl aces where form-i n-pl ace
gaskets are used on the engi ne. Care must be taken
when appl yi ng form-i n-pl ace gaskets. Do not use
form-in-place gasket material unless specified.
Bead si ze, conti nui ty, and l ocati on are of great i mpor-
tance. Too thi n a bead can resul t i n l eakage whi l e too
much can resul t i n spi l l -over, a conti nuous bead of
the proper wi dth i s essenti al to obtai n a l eak-free
joi nt.
Two types of form-i n-pl ace gasket materi al s are
used i n the engi ne. Mopar Si l i cone Rubber Adhe-
si ve Seal ant and Mopar Gasket Maker, (anaerobi c)
each have di fferent properti es and cannot be used
i nterchangeabl y.
CAUTION: Silicone sealer and anaerobic sealers
each will inhibit the cure of the other and care
should be taken to keep usages separated as much
as possible.
MOPAR SILICONE RUBBER ADHESIVE
SEALANT
Mopar Si l i cone Rubber Adhesi ve Seal ant or
equi val ent, normal l y bl ack i n col or, i s avai l abl e i n
three ounce tubes. Moi sture i n the ai r causes the
Mopar Si l i cone Rubber Adhesi ve Seal ant materi al
to cure. Thi s materi al i s normal l y used on fl exi bl e
metal fl anges. I t has a shel f l i fe of one year and wi l l
not properl y cure i f over age. Al ways i nspect the
package for the expi rati on date before use.
MOPAR GASKET MAKER
Mopar Gasket Maker i s an anaerobi c type gasket
materi al normal l y red i n col or. The materi al cures i n
the absence of ai r when squeezed between two metal -
l i c surfaces. I t wi l l not cure i f l eft i n the uncovered
tube. I t i s normal l y red i n col or. The anaerobi c mate-
ri al i s for use between two machi ned surfaces. Do not
use on fl exi bl e metal fl anges.
MOPAR TORQUE CURE GASKET MAKER
Mopar Torque Cure Gasket Maker i s a uni que
anaerobi c type gasket materi al to be used ONLY
between the bedpl ate and engi ne bl ock. The materi al
cures i n the absence of ai r when torqued between
two metal l i c surfaces. I t wi l l not cure i f l eft i n the
uncovered tube. Thi s anaerobi c materi al i s speci al l y
NS ENGINE 9 - 1
made to seal the area between the bedpl ate and cyl -
i nder bl ock wi thout di sturbi ng the beari ng cl earance
or al i gnment of these components.
GASKET DISASSEMBLY
Parts assembl ed wi th form-i n-pl ace gaskets may be
di sassembl ed wi thout unusual effort. I n some
i nstances, i t may be necessary to l i ghtl y tap the part
wi th a mal l et or other sui tabl e tool to break the seal
between the mati ng surfaces. A fl at gasket scraper
may al so be l i ghtl y tapped i nto the joi nt but care
must be taken not to damage the mati ng surfaces.
SURFACE PREPARATION
Scrape cl ean or wi re brush al l gasket surfaces to
remove al l l oose materi al . I nspect stamped parts to
ensure gasket rai l s are fl at. Gasket surfaces must be
free of oi l and di rt. Make sure ol d gasket materi al i s
removed from bl i nd attachi ng hol es.
FORM-IN-PLACE GASKET APPLICATION
Assembl i ng parts usi ng a form-i n-pl ace gasket
requi res care but i ts easi er then usi ng precut gas-
kets.
Mopar Gasket Maker materi al shoul d be appl i ed
spari ngl y 1 mm (0.040 i n.) di ameter or l ess of seal ant
to one gasket surface. Be certai n the materi al sur-
rounds each mounti ng hol e. Excess materi al can eas-
i l y be wi ped off. Components shoul d be torqued i n
pl ace wi thi n 15 mi nutes. The use of a l ocati ng dowel
i s recommended duri ng assembl y to prevent smear-
i ng the materi al off l ocati on.
The Mopar Si l i cone Rubber Adhesi ve Seal ant
gasket materi al or equi val ent shoul d be appl i ed i n a
conti nuous bead approxi matel y 3 mm (0.120 i n.) i n
di ameter. Al l mounti ng hol es must be ci rcl ed. For
corner seal i ng, a 3.17 or 6.35 mm (1/8 or 1/4 i n.) drop
i s pl aced i n the center of the gasket contact area.
Uncured seal ant may be removed wi th a shop towel s.
Components shoul d be torqued i n pl ace whi l e the
seal ant i s sti l l wet to the touch (wi thi n 10 mi nutes).
The usage of a l ocati ng dowel i s recommended duri ng
assembl y to prevent smeari ng of materi al off l oca-
ti on.
CRANKSHAFT SPROCKET BOLT ACCESS PLUG
An Access pl ug i s l ocated i n the ri ght i nner fender
shi el d. Remove the pl ug and i nsert the proper si ze
socket, extensi on and ratchet, when crankshaft rota-
ti on i s necessary.
ENGINE CORE PLUGS
REMOVAL
Usi ng a bl unt tool such as a dri ft or a screwdri ver
and a hammer, stri ke the bottom edge of the cup
pl ug (Fi g. 1). Wi th the cup pl ug rotated, grasp fi rml y
wi th pl i ers or other sui tabl e tool and remove pl ug
(Fi g. 1).
CAUTION: Do not drive cup plug into the casting
as restricted cooling can result and cause serious
engine problems.
INSTALLATION
Thoroughl y remove al l rust and cl ean i nsi de of cup
pl ug hol e i n cyl i nder bl ock or head. Be sure to
remove ol d seal er. Li ghtl y coat i nsi de of cup pl ug hol e
wi th seal er. Make certai n the new pl ug i s cl eaned of
al l oi l or grease. Usi ng proper dri ve pl ug, dri ve pl ug
i nto hol e so that the sharp edge of the pl ug i s at
l east 0.5 mm (0.020 i nch.) i nsi de the l ead i n chamfer
(Fi g. 1).
I t i s i n not necessary to wai t for curi ng of the seal -
ant. The cool i ng system can be refi l l ed and the vehi -
cl e pl aced i n servi ce i mmedi atel y.
ENGINE PERFORMANCE
I f a l oss of performance i s noti ced, ti mi ng bel t or
chai n may have ski pped one or two teeth. Camshaft
and crankshaft ti mi ng shoul d be checked. Refer to
Group 9, Engi ne Ti mi ng bel t or chai n i nstal l ati on.
I t i s i mportant that the vehi cl e i s operati ng to i ts
opti mum performance l evel to mai ntai n fuel economy
and l owest vehi cl e emi ssi ons. I f vehi cl e i s not operat-
i ng to these standards, refer to Engi ne Di agnosi s out-
l i ned i s thi s secti on. The fol l owi ng procedures can
assi st i n achi evi ng the proper engi ne di agnosi s.
(1) Test cranki ng amperage draw. Refer to Group
8B, Starti ng.
(2) Check i ntake mani fol d for vacuum l eaks.
(3) Perform cyl i nder compressi on pressure test.
Refer to Engi ne Di agnosi s, outl i ned i n thi s secti on.
(4) Cl ean or repl ace spark pl ugs as necessary and
adjust gap as speci fi ed i n Group 8D, I gni ti on System.
Ti ghten to speci fi cati ons.
Fig. 1 Core Hole Plug Removal
9 - 2 ENGINE NS
(5) Test resi stance of spark pl ug cabl es. Refer to
Group 8D, I gni ti on System.
(6) Test i gni ti on coi l s pri mary and secondary resi s-
tance. Repl ace parts as necessary. Refer to Group 8D,
I gni ti on System.
(7) Check fuel pump pressure at i dl e and di fferent
RPM ranges. Refer to Group 14, Fuel System for
Speci fi cati ons.
(8) The ai r fi l ter el ements shoul d be repl aced as
speci fi ed i n Group 0, Lubri cati on and Mai ntenance.
(9) I nspect crankcase venti l ati on system as out-
l i ned i n Group 25, Emi ssi on Control Systems.
(10) Road test vehi cl e as a fi nal test.
HONING CYLINDER BORES
(1) Used careful l y, the cyl i nder bore resi zi ng hone
C-823 equi pped wi th 220 gri t stones, i s the best tool
for thi s job. I n addi ti on to degl azi ng, i t wi l l reduce
taper and out-of-round as wel l as removi ng l i ght
scuffi ng, scori ng or scratches. Usual l y a few strokes
wi l l cl ean up a bore and mai ntai n the requi red l i m-
i ts.
(2) Degl azi ng of the cyl i nder wal l s may be done
usi ng a cyl i nder surfaci ng hone, Tool C-3501,
equi pped wi th 280 gri t stones, i f the cyl i nder bore i s
strai ght and round. 20-60 strokes dependi ng on the
bore condi ti on, wi l l be suffi ci ent to provi de a sati sfac-
tory surface. I nspect cyl i nder wal l s after each 20
strokes, usi ng a l i ght honi ng oi l . Do not use engine
or transmission oil, mineral spirits or kerosene.
(3) Honi ng shoul d be done by movi ng the hone up
and down fast enough to get a cross-hatch pattern.
When hone marks intersect at 50-60 degrees, the
cross hatch angl e i s most sati sfactory for proper seat-
i ng of ri ngs (Fi g. 2).
(4) A control l ed hone motor speed between
200-300 RPM i s necessary to obtai n the proper cross-
hatch angl e. The number of up and down strokes per
mi nute can be regul ated to get the desi red 50-60
degree angl e. Faster up and down strokes i ncrease
the cross-hatch angl e.
(5) After honi ng, i t i s necessary that the bl ock be
cl eaned agai n to remove al l traces of abrasi ve.
CAUTION: Ensure all abrasives are removed from
engine parts after honing. It is recommended that a
solution of soap and hot water be used with a
brush and the parts then thoroughly dried. The bore
can be considered clean when it can be wiped
clean with a white cloth and cloth remains clean.
Oil the bores after cleaning to prevent rusting.
MEASURING MAIN BEARING AND CONNECTING
ROD BEARING CLEARANCES
PLASTIGAGE METHOD
Engi ne crankshaft beari ng cl earances can be deter-
mi ned by use of Pl asti gage or equi val ent. The fol l ow-
i ng i s the recommended procedure for the use of
Pl asti gage:
NOTE: The total clearance of the main bearings
can only be determined by removing the weight of
the crankshaft. This can be accomplished by either
of two methods:
PREFERRED METHOD
Shi mmi ng the beari ngs adjacent to the beari ng to
be checked i n order to remove the cl earance between
upper beari ng shel l and the crankshaft. Thi s can be
accompl i shed by pl aci ng a mi ni mum of 0.254 mm
(0.010 i n.) shi m (e. g. cardboard, matchbook cover,
etc.) between the beari ng shel l and the beari ng cap
on the adjacent beari ngs and ti ghteni ng bol ts to
14-20 Nm (10-15 ft. l bs.). The number of mai n bear-
i ng wi l l vary from engi ne to engi ne.
Fig. 2 Cylinder Bore Cross-Hatch Pattern
Fig. 3 Plastigage Placed in Lower Shell
NS ENGINE 9 - 3
ENGINE WITH 5 MAIN BEARINGS
When checki ng #1 mai n beari ng shi m #2 mai n
beari ng.
When checki ng #2 mai n beari ng shi m #1 & 3
mai n beari ng.
mai n beari ng.
mai n beari ng.
beari ng.
ENGINE WITH 4 MAIN BEARING
beari ng.
When checki ng #2 mai n beari ng shi m #1 & #3
mai n beari ng.
When checki ng #3 mai n beari ng shi m #2 & #4
mai n beari ng.
beari ng.
NOTE: REMOVE ALL SHIMS BEFORE REASSEM-
BLING ENGINE
ALTERNATIVE METHOD
The wei ght of the crankshaft can be supported by a
jack under the counterwei ght adjacent to the beari ng
bei ng checked.
PLASTIGAGE PROCEDURE
(1) Remove oi l fi l m from surface to be checked.
Pl asti gage i s sol ubl e i n oi l .
(2) Pl ace a pi ece of Pl asti gage across the enti re
wi dth of the beari ng shel l i n the cap approxi matel y
6.35 mm (1/4 i n.) off center and away from the oi l
hol es (Fi g. 3). (I n addi ti on, suspected areas can be
checked by pl aci ng the Pl asti gage i n the suspected
area). Torque the beari ng cap bol ts of the beari ng
bei ng checked to the proper speci fi cati ons.
(3) Remove the beari ng cap and compare the
wi dth of the fl attened Pl asti gage (Fi g. 4) wi th the
metri c scal e provi ded on the package. Locate the
band cl osest to the same wi dth. Thi s band shows the
amount of cl earance i n thousandths of a mi l l i meter.
Di fferences i n readi ngs between the ends i ndi cate the
amount of taper present. Record al l readi ngs taken.
Refer to Engi ne Speci fi cati ons. Plastigage gener-
ally is accompanied by two scales. One scale is
in inches, the other is a metric scale.
NOTE: Plastigage is available in a variety of clear-
ance ranges. Use the most appropriate range for
the specifications you are checking.
CONNECTING ROD BEARING CLEARANCE
Engi ne connecti ng rod beari ng cl earances can be
determi ned by use of Pl asti gage or equi val ent. The
fol l owi ng i s the recommended procedure for the use
of Pl asti gage:
(1) Rotate the crankshaft unti l the connecti ng rod
to be checked i s at the bottom of i ts stroke.
wi dth of the beari ng shel l i n the beari ng cap approx-
i matel y 6.35 mm (1/4 i n.) off center and away from
the oi l hol e (Fi g. 3). I n addi ti on, suspect areas can be
checked by pl aci ng pl asti gage i n the suspect area.
(4) Assembl e the rod cap wi th Pl asti gage i n pl ace.
Ti ghten the rod cap to the speci fi ed torque. Do not
rotate the crankshaft while assembling the cap
or the Plastigage may be smeared, giving inac-
curate results.
(5) Remove the beari ng cap and compare the
wi dth of the fl attened Pl asti gage (Fi g. 4) wi th the
scal e provi ded on the package. Locate the band cl os-
est to the same wi dth. Thi s band i ndi cates the
amount of oi l cl earance. Di fferences i n readi ngs
between the ends i ndi cate the amount of taper
present. Record al l readi ngs taken. Refer to Engi ne
Speci fi cati ons. Plastigage generally is accompa-
nied by two scales. One scale is in inches, the
other is a metric scale. If the bearing clearance
exceeds 0.076 mm (0.003 in.) replace bearing.
NOTE: Plastigage is available in a variety of clear-
ance ranges. Use the most appropriate range for
the specifications you are checking.
REPAIR OF DAMAGED OR WORN THREADS
Damaged or worn threads (i ncl udi ng al umi num
head spark pl ug threads) can be repai red. Essen-
ti al l y, thi s repai r consi sts of dri l l i ng out worn or
damaged threads, tappi ng the hol e wi th a speci al
Hel i -Coi l Tap, (or equi val ent) and i nstal l i ng an i nsert
i nto the tapped hol e. Thi s bri ngs the hol e back to i ts
ori gi nal thread si ze.
Fig. 4 Clearance Measurement
9 - 4 ENGINE NS
CAUTION: Be sure that the tapped holes maintain
the original centerline.
Hel i -Coi l tool s and i nserts are readi l y avai l abl e
from automoti ve parts jobbers.
HYDROSTATIC LOCKED ENGINE
When an engi ne i s suspected to be hydrostati cal l y
l ocked, regardl ess of what caused the probl em, these
steps shoul d be used.
CAUTION: Do Not Use Starter Motor To Rotate
Engine, severe damage may occur.
(1) I nspect ai r cl eaner, i nducti on system and
i ntake mani fol d to i nsure system i s dry and cl ear of
forei gn materi al .
(2) Remove negati ve battery cabl e.
(3) Pl ace a shop towel around the spark pl ugs
when removi ng them from the engi ne. Thi s wi l l catch
any fl ui d that may possi bl y be i n the cyl i nder under
pressure.
(4) Wi th al l spark pl ugs removed, rotate engi ne
crankshaft usi ng a breaker bar and socket.
(5) I denti fy the fl ui d i n the cyl i nder(s) (i .e., cool -
ant, fuel , oi l or other).
(6) Make sure al l fl ui d has been removed from the
cyl i nders. I nspect engi ne for damage (i .e., Connecti ng
Rods, Pi stons, Val ves etc.)
(7) Repai r engi ne or components as necessary to
prevent thi s probl em from occurri ng agai n.
CAUTION: Squirt approximately 1 teaspoon of oil
into cylinders, rotate engine to lubricate the cylin-
der walls to prevent damage on restart.
(8) I nstal l new spark pl ugs.
(9) Drai n engi ne oi l and remove oi l fi l ter.
(10) Fi l l engi ne wi th speci fi ed amount of approved
oi l and i nstal l new oi l fi l ter.
(11) Connect negati ve battery cabl e.
(12) Start engi ne and check for any l eaks.
ENGINE OIL
Chec king Oil Level
To assure proper engi ne l ubri cati on, the engi ne oi l
must be mai ntai ned at the correct l evel . Check the
oi l l evel at regul ar i nterval s, such as every fuel stop.
The best ti me to check the oi l l evel i s about 5 mi n-
utes after a ful l y warmed-up engi ne i s shut off, or
before starti ng the vehi cl e after i t has sat overni ght.
Checki ng the oi l whi l e the vehi cl e i s on l evel
ground, wi l l i mprove the accuracy of the oi l l evel
readi ngs. For 2.4L, 3.3L and 3.8L engi nes, mai ntai n
the oi l l evel between the MI N and MAX marki ngs on
the di psti ck. Addi ng one quart of oi l when the read-
i ng i s at the MI N mark wi l l resul t i n a MAX readi ng
on these engi nes. For the 3.0L engi ne, add one ful l
quart when the l evel on the di psti ck i s at or bel ow
the ADD mark.
ENGINE OIL SERVICE
WARNING: NEW OR USED ENGINE OIL CAN BE
IRRITATING TO THE SKIN. AVOID PROLONGED OR
REPEATED SKIN CONTACT WITH ENGINE OIL.
CONTAMINANTS IN USED ENGINE OIL, CAUSED BY
INTERNAL COMBUSTION, CAN BE HAZARDOUS TO
YOUR HEALTH. THOROUGHLY WASH EXPOSED
SKIN WITH SOAP AND WATER. DO NOT WASH
SKIN WITH GASOLINE, DIESEL FUEL, THINNER, OR
SOLVENTS, HEALTH PROBLEMS CAN RESULT. DO
NOT POLLUTE, DISPOSE OF USED ENGINE OIL
PROPERLY. CONTACT YOUR DEALER OR GOVERN-
MENT AGENCY FOR LOCATION OF COLLECTION
CENTER IN YOUR AREA.
ENGINE OIL SPECIFICATION
CAUTION: Do not use non-detergent or straight
mineral oil when adding or changing crankcase
lubricant. Engine failure can result.
NS ENGINE 9 - 5
API SERVICE GRADE CERTIFIED
Use an engi ne oi l that i s API Servi ce Grade Certi -
fi ed. MOPAR provi des engi ne oi l s that conforms to
thi s servi ce grade.
SAE VISCOSITY
An SAE vi scosi ty grade i s used to speci fy the vi s-
cosi ty of engi ne oi l . Use onl y, engi ne oi l s wi th mul ti -
pl e vi scosi ti es such as 5W-30 or 10W-30. These are
speci fi ed wi th a dual SAE vi scosi ty grade whi ch i ndi -
cates the col d-to-hot temperature vi scosi ty range.
Sel ect an engi ne oi l that i s best sui ted to your par-
ti cul ar temperature range and vari ati on (Fi g. 5).
ENERGY CONSERVING OIL
An Energy Conservi ng type oi l i s recommended for
gasol i ne engi nes. They are desi gnated as ei ther
ENERGY CONSERVI NG or ENERGY CONSERV-
I NG I I .
CONTAINER IDENTIFICATION
Standard engi ne oi l i denti fi cati on notati ons have
been adopted to ai d i n the proper sel ecti on of engi ne
oi l . The i denti fyi ng notati ons are l ocated on the l abel
of engi ne oi l pl asti c bottl es and the top of engi ne oi l
cans (Fi g. 6).
ENGINE OIL CHANGE
Change engi ne oi l at mi l eage and ti me i nterval s
descri bed i n the Mai ntenance Schedul e.
TO CHANGE ENGINE OIL
Run engi ne unti l achi evi ng normal operati ng tem-
perature.
(1) Posi ti on the vehi cl e on a l evel surface and turn
engi ne off.
Refer to Hoi sti ng and Jacki ng Recommendati ons.
(3) Remove oi l fi l l cap.
(4) Pl ace a sui tabl e drai n pan under crankcase
drai n.
(5) Remove drai n pl ug from crankcase and al l ow
oi l to drai n i nto pan. I nspect drai n pl ug threads for
stretchi ng or other damage. Repl ace drai n pl ug and
gasket i f damaged.
(6) I nstal l drai n pl ug i n crankcase.
(7) Lower vehi cl e and fi l l crankcase wi th speci fi ed
type and amount of engi ne oi l descri bed i n thi s sec-
ti on.
(8) I nstal l oi l fi l l cap.
(9) Start engi ne and i nspect for l eaks.
(10) Stop engi ne and i nspect oi l l evel .
Fig. 5 Temperature/Engine Oil Viscosity
Fig. 6 Engine Oil Container Standard Notations
9 - 6 ENGINE NS
ENGINE DIAGNOSIS
INDEX
page page
CYLINDER COMBUSTION
PRESSURE LEAKAGE TEST . . . . . . . . . . . . . . 8
CYLINDER COMPRESSION PRESSURE TEST . . 7
ENGINE DIAGNOSISMECHANICAL . . . . . . . . . 12
ENGINE DIAGNOSISPERFORMANCE . . . . . . 10
INSPECTION
(ENGINE OIL LEAKS IN GENERAL) . . . . . . . . . 8
INTAKE MANIFOLD LEAKAGE DIAGNOSIS . . . . . 7
LASH ADJUSTER (TAPPET)
NOISE DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . 8
GENERAL INFORMATION
Engi ne di agnosi s i s hel pful i n determi ni ng the
causes of mal functi ons.
These mal functi ons may be cl assi fi ed as ei ther
mechani cal (e.g., a strange noi se), or performance
(e.g., engi ne i dl es rough and stal l s).
Refer to the Servi ce Di agnosi sMechani cal Chart
and the Servi ce Di agnosi sPerformance Chart, for
possi bl e causes and correcti ons of mal functi ons. Refer
to Group 14, Fuel System, for the fuel system di ag-
nosi s.
Addi ti onal tests and di agnosti c procedures may be
necessary for speci fi c engi ne mal functi ons that can-
not be i sol ated wi th the Servi ce Di agnosi s charts.
I nformati on concerni ng addi ti onal tests and di agno-
si s i s provi ded wi thi n the fol l owi ng:
Cyl i nder Compressi on Pressure Test
Cyl i nder Combusti on Pressure Leakage Test
Engi ne Cyl i nder Head Gasket Fai l ure Di agnosi s
I ntake Mani fol d Leakage Di agnosi s
INTAKE MANIFOLD LEAKAGE DIAGNOSIS
An i ntake mani fol d ai r l eak i s characteri zed by
l ower than normal mani fol d vacuum. Al so, one or
more cyl i nders may not be functi oni ng.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR THE FAN.
DO NOT WEAR LOOSE CLOTHING.
(1) Start the engi ne.
(2) Spray a smal l stream of water (Spray Bottl e) at
the suspected l eak area.
(3) I f a change i n RPMS, the area of the suspected
l eak has been found.
(4) Repai r as requi red.
CYLINDER COMPRESSION PRESSURE TEST
The resul ts of a cyl i nder compressi on pressure test
can be uti l i zed to di agnose several engi ne mal func-
ti ons.
Ensure the battery i s compl etel y charged and the
engi ne starter motor i s i n good operati ng condi ti on.
Otherwi se the i ndi cated compressi on pressures may
not be val i d for di agnosi s purposes.
(1) Check engi ne oi l l evel and add oi l i f necessary.
(2) Dri ve the vehi cl e unti l engi ne reaches normal
operati ng temperature. Sel ect a route free from traf-
fi c and other forms of congesti on, observe al l traffi c
l aws, and accel erate through the gears several ti mes
bri skl y.
(3) Remove al l spark pl ugs from engi ne. As spark
pl ugs are bei ng removed, check el ectrodes for abnor-
mal fi ri ng i ndi cators foul ed, hot, oi l y, etc. Record cyl -
i nder number of spark pl ug for future reference.
(4) Di sconnect coi l wi re from di stri butor and
secure to good ground to prevent a spark from start-
i ng a fi re (Conventi onal I gni ti on System). For Di rect
I gni ti on System DI S di sconnect the coi l connector.
(5) Be sure throttl e bl ade i s ful l y open duri ng the
compressi on check.
(6) I nsert compressi on gage adaptor i nto the #1
spark pl ug hol e i n cyl i nder head. Crank engi ne unti l
maxi mum pressure i s reached on gage. Record thi s
pressure as #1 cyl i nder pressure.
(7) Repeat the previ ous step for al l remai ni ng cyl -
i nders.
(8) Compressi on shoul d not be l ess than (689kPa)
100 psi and not vary more than 25 percent from cyl -
i nder to cyl i nder.
(9) I f one or more cyl i nders have abnormal l y l ow
compressi on pressures, repeat the compressi on test.
(10) I f the same cyl i nder or cyl i nders repeat an
abnormal l y l ow readi ng on the second compressi on
test, i t coul d i ndi cate the exi stence of a probl em i n
the cyl i nder i n questi on. The recommended com-
pression pressures are to be used only as a
guide to diagnosing engine problems. An engine
should not be disassembled to determine the
NS ENGINE 9 - 7
cause of low compression unless some malfunc-
tion is present.
(11) Cl ean or repl ace spark pl ugs as necessary
and adjust gap as speci fi ed i n Group 8, El ectri cal .
Ti ghten to speci fi cati ons.
(12) Test resi stance of spark pl ug cabl es. Refer to
Group 8, El ectri cal I gni ti on System Secondary Ci r-
cui t I nspecti on.
(13) Test coi l output vol tage, pri mary and second-
ary resi stance. Repl ace parts as necessary. Refer to
Group 8, El ectri cal I gni ti on System.
(14) Check fuel pump pressure at i dl e and di ffer-
ent RPM ranges. Refer to Group 14, Fuel System for
Speci fi cati ons.
(15) The ai r fi l ter el ements shoul d be repl aced as
speci fi ed i n Group 0, Lubri cati on and Mai ntenance,.
(16) I nspect crankcase venti l ati on system as out
l i ned i n Group 0, Lubri cati on and Mai ntenance. For
emi ssi on control s see Group 25, Emi ssi on Control s
for servi ce procedures.
(17) I nspect and adjust accessory bel t dri ves refer-
ri ng to Group 7, Cool i ng System, Accessory Dri ve
Bel ts for proper adjustments.
(18) Road test vehi cl e as a fi nal test.
CYLINDER COMBUSTION PRESSURE LEAKAGE
TEST
The combusti on pressure l eakage test provi des an
accurate means for determi ni ng engi ne condi ti on.
Combusti on pressure l eakage testi ng wi l l detect:
Exhaust and i ntake val ve l eaks (i mproper seat-
i ng).
Leaks between adjacent cyl i nders or i nto water
jacket.
Any causes for combusti on/compressi on pressure
l oss.
WARNING: DO NOT REMOVE THE RADIATOR CAP
WITH THE SYSTEM HOT AND UNDER PRESSURE
BECAUSE SERIOUS BURNS FROM COOLANT CAN
OCCUR.
Check the cool ant l evel and fi l l as requi red. DO
NOT i nstal l the radi ator cap.
Start and operate the engi ne unti l i t attai ns nor-
mal operati ng temperature, then turn the engi ne
OFF.
Cl ean spark pl ug recesses wi th compressed ai r.
Remove the spark pl ugs.
Remove the oi l fi l l er cap.
Remove the ai r cl eaner.
Cal i brate the tester accordi ng to the manufactur-
ers i nstructi ons. The shop ai r source for testi ng
shoul d mai ntai n 483 kPa (70 psi ) mi ni mum, 1 379
kPa (200 psi ) maxi mum and 552 kPa (80 psi ) recom-
mended.
Perform the test procedures on each cyl i nder
accordi ng to the tester manufacturers i nstructi ons.
Whi l e testi ng, l i sten for pressuri zed ai r escapi ng
through the throttl e body, tai l pi pe and oi l fi l l er cap
openi ng. Check for bubbl es i n the radi ator cool ant.
Al l gauge pressure i ndi cati ons shoul d be equal ,
wi th no more than 25% l eakage.
FOR EXAMPLE: At 552 kPa (80 psi ) i nput pres-
sure, a mi ni mum of 414 kPa (60 psi ) shoul d be mai n-
tai ned i n the cyl i nder.
LASH ADJUSTER (TAPPET) NOISE DIAGNOSIS
A tappet-l i ke noi se may be produced from several
i tems. Check the fol l owi ng i tems.
(1) Engi ne oi l l evel too hi gh or too l ow. Thi s may
cause aerated oi l to enter the adjusters and cause
them to be spongy.
(2) I nsuffi ci ent runni ng ti me after rebui l di ng cyl i n-
der head. Low speed runni ng up to 1 hour may be
requi red.
(3) Duri ng thi s ti me, turn engi ne off and l et set for
a few mi nutes before restarti ng. Repeat thi s several
ti mes after engi ne has reached normal operati ng
temperature.
(4) Low oi l pressure.
(5) The oi l restri ctor pressed i nto the verti cal oi l
passage to the cyl i nder head i s pl ugged wi th debri s.
(6) Ai r i ngested i nto oi l due to broken or cracked
oi l pump pi ck up.
(7) Worn val ve gui des.
(8) Rocker arm ears contacti ng val ve spri ng
retai ner.
(9) Rocker arm l oose, adjuster stuck or at maxi -
mum extensi on and sti l l l eaves l ash i n the system.
(10) Faul ty l ash adjuster.
a. Check l ash adjusters for spongi ness whi l e
i nstal l ed i n cyl i nder head. Depress part of rocker
arm over adjuster. Normal adjusters shoul d feel very
fi rm. Spongy adjusters can be bottomed out easi l y.
b. Remove suspected l ash adjusters, and di sassem-
bl e Do not reuse retainer caps. Do not i nter-
change parts and make sure that care and
cl eanl i ness i s exerci sed i n the handl i ng of parts.
c. Cl ean out di rt and varni sh wi th sol vent.
d. Reassembl e wi th engi ne oi l .
e. Check for spongi ness.
f. I f sti l l spongy, repl ace wi th new adjuster.
INSPECTION (ENGINE OIL LEAKS IN GENERAL)
Begi n wi th a through vi sual i nspecti on of the
engi ne, parti cul arl y at the area of the suspected l eak.
I f an oi l l eak source i s not readi l y i denti fi abl e, the
fol l owi ng steps shoul d be fol l owed:
(1) Do not cl ean or degrease the engi ne at thi s
ti me because some sol vents may cause rubber to
swel l , temporari l y stoppi ng the l eak.
9 - 8 ENGINE NS
(2) Add an oi l sol ubl e dye (use as recommended by
manufacturer). Start the engi ne and l et i dl e for
approxi matel y 15 mi nutes. Check the oi l di psti ck to
make sure the dye i s thoroughl y mi xed as i ndi cated
wi th a bri ght yel l ow col or under a bl ack l i ght.
(3) Usi ng a bl ack l i ght, i nspect the enti re engi ne
for fl uorescent dye, parti cul arl y at the suspected area
of oi l l eak. I f the oi l l eak i s found and i denti fi ed,
repai r per servi ce manual i nstructi ons.
(4) I f dye i s not observed, dri ve the vehi cl e at var-
i ous speeds for approxi matel y 24km (15 mi l es), and
repeat i nspecti on.
(5) If the oil leak source is not positively
identified at this time, proceed wi th the ai r l eak
detecti on test method as fol l ows:
(6) Di sconnect the fresh ai r hose (makeup ai r) at
the cyl i nder head cover and pl ug or cap the ni ppl e on
the cover.
(7) Remove the PCV val ve hose from the cyl i nder
head cover. Cap or pl ug the PCV val ve ni ppl e on the
cover.
(8) Attach an ai r hose wi th pressure gauge and
regul ator to the di psti ck tube.
CAUTION: Do not subject the engine assembly to
more than 20.6 kpa (3 PSI) of test pressure.
(9) Gradual l y appl y ai r pressure from 1 psi to 2.5
psi maxi mum whi l e appl yi ng soapy water at the sus-
pected source. Adjust the regul ator to the sui tabl e
test pressure that provi de the best bubbl es whi ch
wi l l pi npoi nt the l eak source. I f the oi l l eak i s
detected and i denti fi ed, repai r per servi ce manual
procedures.
(10) I f the l eakage occurs at the rear oi l seal area,
refer to the secti on, I nspecti on for Rear Seal Area
Leak.
(11) I f no l eaks are detected, turn off the ai r sup-
pl y and remove the ai r hose and al l pl ugs and caps.
I nstal l the PCV val ve and breather cap hose. Proceed
to next step.
(12) Cl ean the oi l off the suspect oi l l eak area
usi ng a sui tabl e sol vent. Dri ve the vehi cl e at vari ous
speeds approxi matel y 24 km (15 mi l es). I nspect the
engi ne for si gns of an oi l l eak by usi ng a bl ack l i ght.
INSPECTION FOR REAR SEAL AREA LEAKS
Si nce i t i s someti mes di ffi cul t to determi ne the
source of an oi l l eak i n the rear seal area of the
engi ne, a more i nvol ved i nspecti on i s necessary. The
fol l owi ng steps shoul d be fol l owed to hel p pi npoi nt
the source of the l eak.
I f the l eakage occurs at the crankshaft rear oi l seal
area:
(3) Remove torque converter or cl utch housi ng
cover and i nspect rear of bl ock for evi dence of oi l .
Use a bl ack l i ght to check for the oi l l eak. I f a l eak i s
present i n thi s area remove transmi ssi on for further
i nspecti on.
(a) Ci rcul ar spray pattern general l y i ndi cates
seal l eakage or crankshaft damage.
(b) Where l eakage tends to run strai ght down,
possi bl e causes are a porous bl ock, oi l gal l ey cup
pl ug, bedpl ate to cyl i nder bl ock mati ng surfaces
and seal bore. See proper repai r procedures for
these i tems.
(4) I f no l eaks are detected, pressuri zed the crank-
case as outl i ned i n the, I nspecti on (Engi ne oi l Leaks
i n general )
CAUTION: Do not exceed 20.6 kPa (3 psi).
(5) I f the l eak i s not detected, very sl owl y turn the
crankshaft and watch for l eakage. I f a l eak i s
detected between the crankshaft and seal whi l e
sl owl y turni ng the crankshaft, i t i s possi bl e the
crankshaft seal surface i s damaged. The seal area on
the crankshaft coul d have mi nor ni cks or scratches
that can be pol i shed out wi th emery cl oth.
CAUTION: Use extreme caution when crankshaft
polishing is necessary to remove minor nicks and
scratches. The crankshaft seal flange is especially
machined to complement the function of the rear oil
seal.
(6) For bubbl es that remai n steady wi th shaft
rotati on, no further i nspecti on can be done unti l di s-
assembl ed.
(7) After the oi l l eak root cause and appropri ate
correcti ve acti on have been i denti fi ed. Refer to Rear
Crankshaft Seal s, for proper repl acement procedures.
NS ENGINE 9 - 9
ENGINE DIAGNOSIS PERFORMANCE
ENGINE WILL NOT START 1. Weak battery. 1. Test battery. Charge or replace
as necessary.Refer to Group 8A,
Battery.
2. Corroded or loose battery
connections.
2. Clean and tighten battery
connections. Apply a coat of light
mineral grease to terminals.
3. Faulty starter. Test starting system. Refer to Group
8B, Starting.
4. Moisture on ignition wires. 4. Remove moisture from wires.
5. Faulty ignition cables. 5. Replace any cracked or shorted
cables.
6. Faulty coil or control unit. 6. Test and replace as needed.
Refer to Group 8D, Ignition System
7. Incorrect spark plug gap. 7. Set gap. Refer to Group 8D,
Ignition System.
8. Contamination in fuel system. 8. Clean system and replace fuel
filter.
9. Faulty fuel pump. 9. Test fuel pump and replace as
needed. Refer to Group 14, Fuel
System.
ENGINE STALLS OR IDLES
ROUGH
1. Idle speed too low. 1. Test minimum air flow. Refer to
Group 14, Fuel System.
2. Incorrect fuel mixture. 2. Refer to Group 14, Fuel System.
3. Intake manifold leakage. 3. Inspect intake manifold, manifold
gasket, and vacuum hoses. Refer to
Group 11, Exhaust System and
Intake Manifold.
4. Incorrect ignition wiring. 4. Install correct wiring.
5. Faulty coil(s) 5. Test and replace as necessary.
Refer to Group 8D, Ignition System.
ENGINE LOSS OF POWER 1. Dirty or incorrectly gapped plugs. 1. Clean plugs and set gap. Refer to
Group 8D, Ignition System.
filter.
3. Faulty fuel pump. 3. Test and replace as necessary.
Refer to Group 14, Fuel System.
4. Incorrect valve timing. 4. Correct valve timing.
5. Leaking cylinder head gasket. 5. Replace cylinder head gasket.
6. Low compression. 6. Test compression of each
cylinder.
7. Burned, warped, or pitted valves. 7. Replace valves.
8. Plugged or restricted exhaust
system.
8. Install new parts, as necessary.
9. Faulty ignition cables. 9. Replace any cracked or shorted
cables.
10. Faulty coil(s). 10. Test and replace as necessary.
9 - 10 ENGINE NS
ENGINE MISSES ON
ACCELERATION
1. Dirty or incorrectly gapped spark
plugs.
1. Clean spark plugs and set gap.
2. Contamination in Fuel System. 2. Clean fuel system and replace
fuel filter.
3. Burned, warped, or pitted valves. 3. Replace valves.
ENGINE MISSES AT HIGH SPEED 1. Dirty or incorrect spark plug gap. 1. Clean spark plugs and set gap.
3. Dirty fuel injector(s). Test and replace as necessary.
Refer to Group 14, Fuel System.
filter.
NS ENGINE 9 - 11
ENGINE DIAGNOSIS MECHANICAL
NOISY VALVES 1. High or low oil level in
crankcase.
1. Check for correct oil level.
2. Thin or diluted oil. 2. Change oil to correct viscosity.
3. Low oil pressure. 3. Check engine oil level.
4. Dirt in tappets/lash adjusters. 4. Replace rocker arm/hydraulic
lash adjuster assembly.
5. Worn rocker arms. 5. Inspect oil supply to rocker arms.
6. Worn tappets/lash adjusters. 6. Install new rocker arm/hydraulic
7. Worn valve guides. 7. Ream and install new valves with
oversize stems.
8. Excessive runout of valve seats
on valve faces.
8. Grind valve seats and valves.
9. Missing adjuster pivot. 9. Replace rocker arm/hydraulic
CONNECTING ROD NOISE 1. Insuffient oil supply. 1. Check engine oil level.
2. Low oil pressure. 2. Check engine oil level. Inspect oil
pump relief valve and spring.
4. Excessive bearing clearance. 4. Measure bearings for correct
clearance. Repair as necessary.
5. Connecting rod journal
out-of-round.
5. Replace crankshaft or grind
surface.
6. Misaligned connecting rods. 6. Replace bent connecting rods.
MAIN BEARING NOISE 1. Insufficient oil supply. 1. Check engine oil level.
2. Low oil pressure. 2. Check engine oil level. Inspect oil
pump relief valve and spring.
clearance. Repair as necessary.
5. Excessive end play. 5. Check thrust bearing for wear on
flanges.
6. Crankshaft journal out-of-round
or worn.
6. Replace crankshaft or grind
journals.
7. Loose flywheel or torque
converter.
7. Tighten to correct torque.
OIL PRESSURE DROP 1. Low oil level. 1. Check engine oil level.
2. Faulty oil pressure sending unit. 2. Install new sending unit.
3. Low oil pressure. 3. Check sending unit and main
bearing oil clearance.
4. Clogged oil filter. 4. Install new oil filter.
5. Worn parts in oil pump. 5. Replace worn parts or pump.
clearance.
8. Oil pump relief valve stuck. 8. Remove valve and inspect, clean,
or replace.
9. Oil pump suction tube loose. 9. Remove oil pan and install new
tube or clean, if necessary.
10. Oil pump cover warped or
cracked.
10. Install new oil pump.
9 - 12 ENGINE NS
OIL LEAKS 1. Misaligned or deteriorated
gaskets.
1. Replace gasket(s).
2. Loose fastener, broken or porous
metal part.
2. Tighten, repair or replace the
part.
3. Misaligned or deteriorated cup or
threaded plug.
3. Replace as necessary.
OIL CONSUMPTION OR SPARK
PLUGS FOULED
1. PCV system malfunction. 1. Check system and repair as
necessary. Refer to Group 25,
Emission Control Systems.
2. Worn, scuffed or broken rings. 2. Hone cyinder bores. Install new
rings.
3. Carbon in oil ring slots. 3. Install new rings.
4. Rings fitted too tightly in grooves. 4. Remove rings and check
grooves. If groove is not proper
width, replace piston.
5. Worn valve guides. 5. Ream guides and replace valves
with oversize valves and seals.
6. Valve stem seal unseated or
faulty.
6. Repair or replace seal.
NS ENGINE 9 - 13
2.4L ENGINE
INDEX
page page
ENGINE COMPONENTS . . . . . . . . . . . . . . . . . . 15
ENGINE IDENTIFICATION . . . . . . . . . . . . . . . . . 14
ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . 14
CHECKING ENGINE OIL PRESSURE . . . . . . . . . 16
SERVICE PROCEDURES
CRANKSHAFT END PLAY . . . . . . . . . . . . . . . . . 20
FITTING CONNECTING ROD BEARINGS . . . . . 18
FITTING MAIN BEARINGS . . . . . . . . . . . . . . . . . 19
FITTING PISTON RINGS . . . . . . . . . . . . . . . . . . 16
FITTING PISTONS . . . . . . . . . . . . . . . . . . . . . . . 16
VALVE SERVICE RECONDITION . . . . . . . . . . . . 21
BALANCE SHAFTS CARRIER ASSEMBLY . . . . . 30
CAMSHAFT FOLLOWER . . . . . . . . . . . . . . . . . . 30
CAMSHAFT OIL SEALFRONT . . . . . . . . . . . . . 41
CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
CRANKSHAFT OIL SEALFRONT . . . . . . . . . . . 42
CRANKSHAFT OIL SEALREAR . . . . . . . . . . . . 43
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . 46
CYLINDER HEAD COVER . . . . . . . . . . . . . . . . . 28
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . 34
ENGINE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 26
ENGINE MOUNTFRONT . . . . . . . . . . . . . . . . . 23
ENGINE MOUNTLEFT . . . . . . . . . . . . . . . . . . 24
ENGINE MOUNTREAR . . . . . . . . . . . . . . . . . . 25
ENGINE MOUNTRIGHT . . . . . . . . . . . . . . . . . 24
HYDRAULIC LASH ADJUSTER . . . . . . . . . . . . . . 33
OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
PISTON AND CONNECTING ROD . . . . . . . . . . . 49
STRUCTURAL COLLAR . . . . . . . . . . . . . . . . . . . 25
TIMING BELT COVER . . . . . . . . . . . . . . . . . . . . 37
TIMING BELT TENSIONER ASSEMBLY . . . . . . . 40
TIMING BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
VALVE SPRINGS AND
VALVE SEALS IN VEHICLE . . . . . . . . . . . . . . . 33
VALVES AND VALVE SPRINGS . . . . . . . . . . . . . 35
VIBRATION DAMPER . . . . . . . . . . . . . . . . . . . . 36
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . 52
CYLINDER BLOCK . . . . . . . . . . . . . . . . . . . . . . . 54
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . 51
VALVE AND VALVE SPRING . . . . . . . . . . . . . . . . 51
ADJUSTMENTS
ENGINE MOUNTS . . . . . . . . . . . . . . . . . . . . . . . 54
SPECIFICATIONS
2.4L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
TORQUE CHART 2.4L . . . . . . . . . . . . . . . . . . . . 57
SPECIAL TOOLS
2.4L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
ENGINE IDENTIFICATION
The engi ne i denti fi cati on number i s l ocated on the
rear of the cyl i nder bl ock (Fi g. 1).
ENGINE LUBRICATION SYSTEM
OIL PAN
A structural di e cast al umi num oi l pan provi des
l ower engi ne protecti on as wel l as servi ng as the
engi ne oi l reservoi r. Oi l pan i s attached to bl ock and
seal ed wi th a gasket. The oi l pi ckup tube has a
strai ner and cover.
PRESSURE LUBRICATION
Oi l drawn up through the pi ckup tube i s pressur-
i zed by the pump and routed through the ful l fl ow fi l -
ter to the mai n oi l gal l ery runni ng the l ength of the
cyl i nder bl ock. Oi l pi ckup, pump and check val ve pro-
vi de oi l fl ow to the mai n oi l gal l ery.
MAIN/ROD BEARINGS
A di agonal hol e i n each bul khead feeds oi l to each
mai n beari ng. Dri l l ed passages wi thi n the crankshaft
route oi l from mai n beari ng journal s to connecti ng
rod journal s.
CAMSHAFT/HYDRAULIC LASH ADJ USTERS
A verti cal hol e at the number fi ve bul khead routes
pressuri zed oi l through a restri ctor up past a cyl i n-
der head bol t to an oi l gal l ery runni ng the l ength of
the cyl i nder head. The camshaft journal s are par-
ti al l y sl otted to al l ow a predetermi ned amount of
pressuri zed oi l to pass i nto the beari ng cap cavi ti es
wi th smal l hol es di rected to spray l ubri cate the cam-
shaft l obes.
9 - 14 2. 4L ENGINE NS
BALANCE SHAFTS
Bal ance shaft l ubri cati on i s provi ded through an
oi l passage from the number 1 mai n beari ng cap
through the bal ance shaft carri er support l eg. Thi s
passage di rectl y suppl i es oi l to the front beari ngs and
i nternal machi ned passages i n the shafts that routes
oi l from front to rear shaft beari ng journal s
SPLASH LUBRICATION
Oi l returni ng to the pan from pressuri zed compo-
nents suppl i es l ubri cati on to the val ve stems. Cyl i n-
der bores and wri st pi ns are spl ash l ubri cated from
di rected sl ots on the connecti ng rod thrust col l ars.
ENGINE COMPONENTS
BALANCE SHAFTS: 2.4L engi nes are equi pped
wi th two bal ance shafts i nstal l ed i n a carri er
attached to the l ower crankcase. The shafts i ntercon-
nect through gears to rotate i n opposi te di recti ons.
These gears are dri ven by a short chai n from the
crankshaft, to rotate at two ti mes crankshaft speed.
Thi s counterbal ances certai n engi ne reci procati ng
masses.
CYLINDER BLOCK AND BEDPLATE ASSEM-
BLY: A cl osed deck desi gn i s used for cool i ng and
wei ght reducti on wi th water pump mol ded i nto the
bl ock. Nomi nal wal l thi ckness i s 4.5 mm. The bed-
pl ate i ncorporates mai n beari ng caps. Rear seal
retai ner i s i ntegral wi th the bl ock.
CRANKSHAFT: A nodul ar cast i ron crankshaft i s
used. The engi ne has 5 mai n beari ngs, wi th number
3 fl anged to control thrust. The 60 mm di ameter
mai n and 50 mm di ameter crank pi n journal s (al l )
have undercut fi l l ets that are deep rol l ed for added
strength. To evenl y di stri bute beari ng l oads and mi n-
i mi ze i nternal stress, 8 counterwei ghts are used.
Hydrodynami c seal s provi de end seal i ng, where the
crankshaft exi ts the bl ock. Anaerobi c gasket materi al
i s used for parti ng l i ne seal i ng i n the bl ock. A si n-
tered powder metal ti mi ng bel t sprocket i s mounted
on the crankshaft nose. Thi s sprocket provi des
moti ve power; vi a ti mi ng bel t to the camshaft sprock-
ets (provi di ng ti med val ve actuati on) and to the
water pump.
PISTONS: There i s provi si ons for free wheel i ng
val ve trai n. Pi ston has a uni que hei ght. Al l engi nes
use pressed i n pi ston pi ns to attach forged powder
metal connecti ng rods. I ncorporate hex head cap
screw threaded i nto the connecti ng rod. Pi ston and
Rods are servi ced as a assembl y.
PISTONS RINGS: The pi ston ri ngs i ncl ude a
mol ybdenum faced top ri ng for rel i abl e compressi on
Engine2.4L
Fig. 1 Engine Identification
NS 2. 4L ENGINE 9 - 15
seal i ng and a chrome pl ated taper faced i ntermedi ate
ri ng for addi ti onal cyl i nder pressure control . There
are al so standard oi l control ri ngs.
CYLINDER HEAD: Features a Dual Over Head
Camshaft (DOHC) 4 val ves per cyl i nder cross fl ow
desi gn. The val ves are arranged i n two i nl i ne banks,
wi th the ports of the bank of two i ntake val ves per
cyl i nder faci ng toward the radi ator si de of engi ne
and ports of the bank of two exhaust val ves per cyl -
i nder faci ng toward the dash panel . I ncorporates
powder metal val ve gui des and seats. I ntegral oi l gal -
l eys wi thi n the cyl i nder head suppl i es oi l to the
hydraul i c l ash adjusters, camshaft and val ve mecha-
ni sms.
CAMSHAFTS: The nodul ar i ron camshafts have
si x beari ng journal s and 2 cam l obes per cyl i nder.
Fl anges at the rear journal s control camshaft end
pl ay. Provi si on for cam posi ti on sensor i s l ocated on
the i ntake camshaft at the rear of cyl i nder head. A
hydrodynami c oi l seal i s used for oi l control at the
front of the camshaft.
VALVES: 4 val ves per cyl i nder are actuated by
rol l er cam fol l owers whi ch pi vot on stati onary
hydraul i c l ash adjusters. Al l val ves have 6 mm di am-
eter chrome pl ated val ve stems. The val ve si zes are
34.8 mm (1.370 i nch.) di ameter i ntake val ves and
30.5 mm (1.20 i nch.) di ameter exhaust val ves. Vi ton
rubber val ve stem seal s are i ntegral wi th the spri ng
seats. Val ve spri ngs, spri ng retai ners, and l ocks are
conventi onal .
INTAKE MANIFOLD: The i ntake mani fol d i s a
two pi ece al umi num casti ng, attached to the cyl i nder
head wi th ten screws. Thi s l ong branch fan desi gn
enhances l ow and mi dspeed torque, whi l e mi ni mi zi ng
undesi rabl e i nl et noi se.
EXHAUST MANIFOLD: The exhaust mani fol d i s
made of cast i ron for strength and hi gh tempera-
tures.
ENGINE LUBRICATION: Refer to Group 0
Lubri cati on and Mai ntenance for recommended oi l to
be used i n vari ous engi ne appl i cati on. System i s ful l
fl ow fi l trati on, pressure feed type. The oi l pump i s
mounted i n the front engi ne cover and dri ven by the
crankshaft. Pressuri zed oi l i s then routed through
the mai n oi l gal l ery, runni ng the l ength of the cyl i n-
der bl ock, suppl yi ng mai n and rod beari ngs wi th fur-
ther routi ng. Pi stons are l ubri cated from rod beari ng
throw off and l ubri cati ng sl ots on the connecti ng rod
assembl i es. Camshaft and val ve mechani sms are
l ubri cated from a ful l l ength cyl i nder head oi l gal l ery
suppl i ed from the crankcase mai n oi l gal l ery.
CHECKING ENGINE OIL PRESSURE
(1) Remove oi l pressure sendi ng uni t and i nstal l
gauge assembl y C-3292.
(2) Run engi ne unti l thermostat opens.
CAUTION: If oil pressure is 0 at idle, Do Not Run
engine at 3000 RPM
(3) Oi l Pressure: Curb Idle 25 kPa (4 psi ) mi ni -
mum 3000 RPM 170/550 kPa (25/80 psi ).
(4) I f oi l pressure i s 0 at i dl e. Shut off engi ne,
check for pressure rel i ef val ve stuck open or a
cl ogged oi l pi ckup screen.
SERVICE PROCEDURES
FITTING PISTONS
Pi ston and cyl i nder wal l must be cl ean and dry.
Pi ston di ameter shoul d be measured 90 degrees to
pi ston pi n about 14 mm (9/16 i nch.) from the bottom
of the ski rt as shown i n (Fi g. 3). Cyl i nder bores
shoul d be measured hal fway down the cyl i nder bore
and transverse to the engi ne crankshaft center l i ne
shown i n (Fi g. 2). Refer to Cyl i nder Bore and Pi ston
Speci fi cati on Chart.
Correct pi ston to bore cl earance must be estab-
l i shed i n order to assure qui et and economi cal oper-
ati on.
Chrysl er engi nes use pi stons desi gned speci fi cal l y
for each engi ne model . Cl earance and si zi ng l ocati ons
vary wi th respect to engi ne model .
NOTE: Pistons and cylinder bores should be mea-
sured at normal room temperature, 70F (21C).
FITTING PISTON RINGS
(1) Wi pe cyl i nder bore cl ean. I nsert ri ng and push
down wi th pi ston to ensure i t i s square i n bore. The
ri ng gap measurement must be made wi th the ri ng
posi ti oni ng at l east 12 mm (0.50 i nch) from bottom of
cyl i nder bore. Check gap wi th feel er gauge (Fi g. 4).
Refer to speci fi cati on i n Pi ston Ri ng Speci fi cati on
Chart.
(2) Check pi ston ri ng to groove si de cl earance (Fi g.
5). Refer to speci fi cati on i n Pi ston Ri ng Speci fi cati on
Chart.
PISTON RINGSINSTALLATION
(1) I nstal l ri ngs wi th manufacturers I .D. mark fac-
i ng up, to the top of the pi ston (Fi g. 6).
CAUTION: Install piston rings in the following
order:
Fig. 2 Checking Cylinder Bore Size
CYLINDER BORE AND PISTON
SPECIFICATION CHART
Standard Bore Maximum
Out-Of-Round
Maximum
Taper
87.5 mm 0.051 mm 0.051 mm
(3.445 in.) (0.002 in.) (0.002 in.)
Standard Piston Size
87.450 - 87.468 mm (3.4434 - 3.4441 in.)
Piston To Bore Clearance
0.024 - 0.057 mm (0.0009 - 0.0022 in.)
Note: Measurements taken at Piston Size Location.
Fig. 3 Piston Measurement
Fig. 4 Piston Ring Gap
PISTON RING SPECIFICATION CHART
Ring Position Ring Gap Wear Limit
Upper Ring 0.025 to 0.51 mm
(0.0098 to 0.020 in.)
0.8 mm
(0.031 in.)
Intermediate
Ring
0.23 to 0.48 mm
(0.009 to 0.018 in.)
0.8 mm
(0.031 in.)
Oil Control
Ring
0.25 to 0.64 mm
(0.0098 to 0.025 in.)
1.0 mm
(0.039 in.)
Ring Position Groove Clearance Max.
Clearance
Upper Ring 0.030 to 0.080 mm
(0.0011 to 0.0031 in.)
0.10 mm
(0.004 in.)
Intermediate
Ring
0.025 to 0.065 mm
(0.0010 to 0.0026 in.)
0.10 mm
(0.004 in.)
Oil Control Ring - Three Piece. Oil Ring Side Rails
Must Be Free To Rotate After Assembly.
Fig. 5 Piston Ring Side Clearance
a. Oi l ri ng expander.
b. Upper oi l ri ng si de rai l .
c. Lower oi l ri ng si de rai l .
d. No. 2 I ntermedi ate pi ston ri ng.
e. No. 1 Upper pi ston ri ng.
(2) I nstal l the si de rai l by pl aci ng one end
between the pi ston ri ng groove and the expander.
Hol d end fi rml y and press down the porti on to be
i nstal l ed unti l si de rai l i s i n posi ti on. Do not use a
piston ring expander (Fi g. 7).
(3) I nstal l upper si de rai l fi rst and then the l ower
si de rai l .
(4) I nstal l No. 2 pi ston ri ng and then No. 1 pi ston
ri ng.
(5) Posi ti on pi ston ri ng end gaps as shown i n (Fi g.
8).
(6) Posi ti on oi l ri ng expander gap at l east 45
from the si de rai l gaps but not on the pi ston pi n cen-
ter or on the thrust di recti on. Staggeri ng ri ng gap i s
i mportant for oi l control .
FITTING CONNECTING ROD BEARINGS
Engi ne connecti ng rod beari ng cl earances can be
determi ned by use of Pl asti gage or equi val ent. The
fol l owi ng i s the recommended procedure for the use
of Pl asti gage:
(1) Rotate the crankshaft unti l the connecti ng rod
to be checked i s at the bottom of i ts stroke.
wi dth of the beari ng shel l i n the beari ng cap approx-
i matel y 6.35 mm (1/4 i n.) off center and away from
the oi l hol e (Fi g. 9). I n addi ti on, suspect areas can be
checked by pl aci ng pl asti gage i n the suspect area.
(4) Before assembl i ng the rod cap wi th Pl asti gage
i n pl ace, the crankshaft must be rotated unti l the
connecti ng rod bei ng checked starts movi ng toward
the top of the engi ne. Onl y then shoul d the cap be
assembl ed and torqued to speci fi cati ons. Do not
rotate the crankshaft while assembling the cap
or the Plastigage may be smeared, giving inac-
curate results.
(5) Remove the beari ng cap and compare the wi dth
of the fl attened Pl asti gage (Fi g. 9) wi th the metri c
Fig. 6 Piston Ring Installation
Fig. 7 Installing Side Rail
Fig. 8 Piston Ring End Gap Position
Fig. 9 Measuring Plastigage Width
scal e provi ded on the package. Locate the band cl os-
est to the same wi dth. Thi s band shows the amount
of cl earance i n thousandths of a mi l l i meter. Di ffer-
ences i n readi ngs between the ends i ndi cate the
amount of taper present. Record al l readi ngs taken.
Refer to Engi ne Speci fi cati ons. Plastigage gener-
ally is accompanied by two scales. One scale is
in inches, the other is a metric scale.
(6) Pl asti gage i s avai l abl e i n a vari ety of cl earance
ranges. The 0.025-0.076 mm (.001-.003 i n.) i s usual l y
the most appropri ate for checki ng engi ne beari ng
proper speci fi cati ons.
FITTING MAIN BEARINGS
Refer to the Engi ne General I nformati on Secti on
for Measuri ng Mai n Beari ngs. For Crankshaft speci -
fi cati ons refer to Crankshaft Speci fi cati on Chart.
CRANKSHAFT MAIN BEARINGS
The crankshaft i s supported i n fi ve mai n beari ngs.
Al l upper and l ower beari ng shel l s i n the crankcase
have oi l grooves. The number three l ower mai n
thrust beari ng i s pl ai n. Crankshaft end pl ay i s con-
trol l ed by a fl anged beari ng on the number three
mai n beari ng journal (Fi g. 10).
Upper and l ower Number 3 beari ng hal ves are
fl anged to carry the crankshaft thrust l oads and are
NOT i nterchangeabl e wi th any other beari ng hal ves
i n the engi ne (Fi g. 10). Al l beari ng cap bol ts removed
duri ng servi ce procedures are to be cl eaned and oi l ed
before i nstal l ati on. Beari ng shel l s are avai l abl e i n
standard and the fol l owi ng undersi zed: 0.025 mm
(0.001 i n.) and 0.250 mm (0.010 i n.). Never i nstal l an
undersi ze beari ng that wi l l reduce cl earance bel ow
speci fi cati ons.
MAIN BEARING INSTALLATION
(1) I nstal l the mai n beari ng shel l s wi th the l ubri -
cati on groove i n the cyl i nder bl ock (Fi g. 11).
(2) Make certai n oi l hol es i n bl ock l i ne up wi th oi l
hol es i n beari ngs. Beari ng tabs must seat i n the
bl ock tab sl ots.
CAUTION: Do not get oil on the bedplate mating
surface. It will may effect the sealer ability to seal
the bedplate to cylinder block.
(3) Oi l the beari ngs and journal s and i nstal l
crankshaft.
CAUTION: Use only the specified anaerobic sealer
on the bedplate or damage may occur to the
engine. Ensure that both cylinder block and bed-
plate surfaces are clean.
CRANKSHAFT SPECIFICATION CHART
Crankshaft End-Play
New Part: 0.09 - 0.24 mm (0.0035 - 0.0094 in.)
Wear Limit: 0.37 mm (0.015 in.)
Main Bearing Clearance
New Part: 0.018 - 0.058 mm (0.0007 - 0.0023 in.)
Connecting Rod Bearing Clearance
New Part: 0.025 - 0.071 mm (0.001 - 0.003 in.)
Crankshaft Journal Sizes
Main Bearing Journal Diameter
Standard 60.000 0.008 mm (2.3622 0.0003 in.)
1 st Undersize 59.975 0.008 mm (2.361 0.0003 in.)
Connecting Rod Journals
Standard 49.992 0.008 mm (1.968 0.0003 in.)
1 st Undersize 49.967 0.008 mm (1.967 0.0003 in.)
Fig. 10 Main Bearing Identification
Fig. 11 Installing Main Bearing Upper Shell
(4) Appl y 1.5 to 2.0 mm (0.059 to 0.078 i n.) bead
of anaerobi c seal er Mopar Torque Cure Gasket
Maker to cyl i nder bl ock as shown i n (Fi g. 12).
(5) I nstal l l ower mai n beari ngs i nto mai n beari ng
cap/bedpl ate. Make certai n the beari ng tabs are
seated i nto the bedpl ate sl ots. I nstal l the mai n bear-
i ng/bedpl ate i nto engi ne bl ock.
(6) Before i nstal l i ng bol ts, l ubri cate the threads
wi th cl ean engi ne oi l , wi pe off any excess oi l .
(7) I nstal l mai n beari ng bedpl ate to engi ne bl ock
bol ts 11, 17 and 20 fi nger ti ght. Ti ghten these bol ts
down together unti l the bedpl ate contacts the cyl i n-
der bl ock.
(8) To ensure correct thrust beari ng al i gnment,
perform the fol l owi ng steps:
Step 1: Rotate crankshaft unti l number 4 pi ston
i s at TDC.
Step 2: Move crankshaft rearward to l i mi ts of
travel .
Step 3: Then, move crankshaft forward to l i mi ts
of travel .
Step 4: Wedge an appropri ate tool between the
rear of the cyl i nder bl ock (NOT BED PLATE) and
the rear crankshaft counterwei ght. Thi s wi l l hol d the
crankshaft i n i ts furthest forward posi ti on.
Step 5: I nstal l and ti ghten bol ts (1 10) i n
sequence shown i n (Fi g. 13) to 41 Nm (30 ft. l bs.).
Step 6: Remove wedge tool used to hol d crank-
shaft.
(9) Ti ghten bol ts (1 10) agai n to 41 Nm (30 ft.
l bs.) + 1/4 turn i n sequence shown i n (Fi g. 13).
bol ts (11 through 20), and torque each bol t to 28 Nm
(20 ft. l bs.) i n sequence shown i n (Fi g. 13).
(11) After the mai n beari ng bedpl ate i s i nstal l ed,
check the crankshaft turni ng torque. The turni ng
torque shoul d not exceed 5.6 Nm (50 i n. l bs.).
CRANKSHAFT END PLAY
(1) Mount a di al i ndi cator to front of engi ne, l ocat-
i ng probe on nose of crankshaft (Fi g. 14).
(2) Move crankshaft al l the way to the rear of i ts
travel .
(3) Zero the di al i ndi cator.
(4) Move crankshaft al l the way to the front and
read the di al i ndi cator. Refer to Crankshaft Speci fi -
cati on Chart for end-pl ay speci fi cati on.
Fig. 12 Main Bearing Caps/Bedplate Sealing
Fig. 13 Main Bearing Caps/Bedplate Torque
Sequence
Fig. 14 Checking Crankshaft End PlayTypical
Crankshaft End-Play
New Part: 0.09 - 0.24mm
(0.0035 - 0.0094 in.)
Wear Limit: 0.37 mm
(0.015 in.)
OPTIONAL CRANKSHAFT END PLAY CHECK
travel usi ng a l ever i nserted between a mai n beari ng
cap and a crankshaft cheek, usi ng care not to dam-
age any beari ng surface. DO NOT l oosen mai n bear-
i ng cap.
(2) Use a feel er gauge between number three
thrust beari ng and machi ned crankshaft surface to
determi ne end pl ay.
VALVE SERVICE RECONDITION
VALVE REMOVAL
(1) Wi th cyl i nder head removed, compress val ve
spri ngs usi ng Speci al Tool C-3422-B or equi val ent.
(2) Remove val ve retai ni ng l ocks, val ve spri ng
retai ners, val ve stem seal s and val ve spri ngs.
(3) Before removi ng val ves, remove any burrs
from valve stem lock grooves to prevent dam-
age to the valve guides. I denti fy val ves to i nsure
i nstal l ati on i n ori gi nal l ocati on.
VALVE INSPECTION
(1) Cl ean val ves thoroughl y and di scard burned,
warped and cracked val ves.
(2) Measure val ve stems for wear. Measure stem
about 60 mm beneath the val ve l ock grooves.
(3) I f val ve stems are worn more than 0.05 mm
(0.002 i n.), repl ace val ve.
VALVE GUIDES
(1) Remove carbon and varni sh deposi ts from
i nsi de of val ve gui des wi th a rel i abl e gui de cl eaner.
(2) Usi ng a smal l hol e gauge and a mi crometer,
measure val ve gui des i n 3 pl aces top, mi ddl e and bot-
tom (Fi g. 15). Refer to Val ve Gui de Speci fi cati on
Chart. Repl ace gui des i f they are not wi thi n speci fi -
cati on.
(3) Check val ve gui de hei ght (Fi g. 16).
TESTING VALVE SPRINGS
(1) Whenever val ves have been removed for i nspec-
ti on, recondi ti oni ng or repl acement, val ve spri ngs
shoul d be tested. As an exampl e, the compressi on
l ength of the spri ng to be tested i s 33.34 mm (1 5/16
i nches). Turn tool tabl e unti l surface i s i n l i ne wi th
the 33.34 mm (1 5/16 i n.) mark on the threaded stud
and the zero mark on the front. Pl ace spri ng over
stud on the tabl e and l i ft compressi ng l ever to set
tone devi ce (Fi g. 17). Pul l on torque wrench unti l
pi ng i s heard. Take readi ng on torque wrench at thi s
i nstant. Mul ti pl y thi s readi ng by two. Thi s wi l l gi ve
the spri ng l oad at test l ength. Fracti onal measure-
ments are i ndi cated on the tabl e for fi ner adjust-
ments. Di scard the spri ngs that do not meet
speci fi cati ons. The Fol l owi ng speci fi cati ons appl y to
both i ntake and exhaust val ve spri ngs;
Val ve Cl osed Nomi nal Tensi on 76 l bs. @ 38.0
mm (1.50 i n.)
Val ve Open Nomi nal Tensi on 136 l bs. @ 29.75
mm (1.17 i n.)
(2) I nspect each val ve spri ng for squareness wi th a
steel square and surface pl ate, test spri ngs from both
ends. I f the spri ng i s more than 1.5 mm (1/16 i nch)
out of square, i nstal l a new spri ng.
REFACING VALVES AND VALVE SEATS
(1) The i ntake and exhaust val ve seats and val ve
face have a 45 and a 45 1/2 degree angl es.
Fig. 15 Checking Wear on Valve GuideTypical
VALVE GUIDE SPECIFICATION CHART
Valve Guide Diameter
Intake and
Exhaust Valve:
5.975 - 6.000 mm
(0.2352 - 0.2362 in.)
Valve Guide Clearance
New Service
Limit
Intake Valve: 0.048 - 0.066 mm
(0.0018 - 0.0025 in.)
0.25 mm
(0.010 in.)
Exhaust Valve: 0.0736 - 0.094 mm
(0.0029 - 0.0037 in.)
Fig. 16 Valve Guide Height
(2) I nspect the remai ni ng margi n after the val ves
are refaced (Fi g. 18). I ntake val ves wi th l ess than 1.2
mm (3/64 i nch.) margi n and Exhaust val ves wi th l ess
than 0.9 mm (1/32 i nch.) margi n shoul d be di scarded.
(3) When refaci ng val ve seats, i t i s i mportant that
the correct si ze val ve gui de pi l ot be used for reseat-
i ng stones. A true and compl ete surface must be
obtai ned.
(4) Measure the concentri ci ty of val ve seat and
val ve gui de usi ng a val ve seat runout di al i ndi cator.
Total runout shoul d not exceed. 0.051 mm (0.002
i nch.) (total i ndi cator readi ng).
(5) I nspect the val ve seat wi th Prussi an bl ue to
determi ne where the val ve contacts the seat. To do
thi s, coat val ve seat LIGHTLY wi th Prussi an bl ue
then set val ve i n pl ace. Rotate the val ve wi th l i ght
pressure. I f the bl ue i s transferred to the center of
val ve face, contact i s sati sfactory. I f the bl ue i s trans-
ferred to top edge of the val ve face, l ower val ve seat
wi th a 15 degrees stone. I f the bl ue i s transferred to
the bottom edge of val ve face rai se val ve seat wi th a
65 degrees stone.
I ntake val ve seat di ameter i s 34.37 34.63 mm
(1.158 1.363 i nch.)
Exhaust val ve seat di ameter i s 29.37 29.63 mm
(1.156 1.166 i nch.)
(6) Val ve seats whi ch are worn or burned can be
reworked, provi ded that correct angl e and seat wi dth
are mai ntai ned. Otherwi se the cyl i nder head must be
repl aced.
(7) When seat i s properl y posi ti oned the wi dth of
i ntake and exhaust seats shoul d be 0.9 to 1.3 mm
(0.35 to 0.051 i nch.) (Fi g. 19).
(8) Check val ve ti p hei ght di mensi ons A after
gri ndi ng the val ve seats or faces (Fi g. 20). Gri nd
val ve ti p to 47.99 mm (1.889 i n.) for exhaust val ve
and 48.04 mm (1.891 i n.) for i ntake val ve when
i nstal l ed i n the head. The val ve ti p chamfer may
Fig. 17 Testing Valve Springs
Intake and Exhaust Valves
VALVE SPECIFICATION CHART
Face Angle
Intake and Exhaust: 44.5-45
Head Diameter
Intake: 34.67 - 34.93 mm
(1.364 - 1.375 in.)
Exhaust: 30.37 - 30.63 mm
(1.195 - 1.205 in.)
Length (Overall)
Intake: 112.76 - 113.32 mm
(4.439 - 4.461 in.)
Exhaust: 109.59 - 110.09 mm
(4.314 - 4.334 in.)
Stem Diameter
Intake: 5.934 - 5.952 mm
(0.2337 - 0.2344 in.)
Exhaust: 5.906 - 5.924 mm
(0.2326 - 0.2333 in.)
Valve Margin
Intake: 1.285 - 1.615 mm
(0.050 - 0.063 in.)
Exhaust: 0.985 - 1.315 mm
(0.038 - 0.051 in.)
Fig. 18 Refacing Intake and Exhaust Valves
need to be reground to prevent seal damage when
the val ve i s i nstal l ed.
VALVE INSTALLATION
(1) Coat val ve stems wi th cl ean engi ne oi l and
i nsert i n cyl i nder head.
(2) I nstal l new val ve stem seal s on al l val ves usi ng
a val ve stem seal tool (Fi g. 21). The val ve stem seal s
shoul d be pushed fi rml y and squarel y over val ve
gui de.
CAUTION: When oversize valves are used, the cor-
responding oversize valve seal must also be used.
Excessive guide wear may result if oversize seals
are not used with oversize valves.
(3) I nstal l val ve spri ngs and retai ners. Compress
val ve spri ngs onl y enough to i nstal l l ocks, taki ng
care not to mi sal i gn the di recti on of compressi on.
Ni cked val ve stems may resul t from mi sal i gnment of
the val ve spri ng compressor.
CAUTION: When depressing the valve spring
retainers with valve spring compressor the locks
can become dislocated. Check to make sure both
locks are in their correct location after removing
tool.
(4) Check the val ve spri ng i nstal l ed hei ght B after
refaci ng the val ve and seat (Fi g. 20). Make sure mea-
surements are taken from top of spri ng seat to the
bottom surface of spri ng retai ner. I f hei ght i s greater
than 38.75 mm (1.525 i n.), i nstal l a .762 mm (0.030
i nch.) spacer under the val ve spri ng seat to bri ng
spri ng hei ght back wi thi n speci fi cati on.
(5) I nstal l rocker arm shafts as previ ousl y
descri bed i n thi s secti on.
(6) Checki ng dry l ash. Dry l ash i s the amount of
cl earance that exi sts between the base ci rcl e of an
i nstal l ed cam and the rocker arm rol l er when the
adjuster i s drai ned of oi l and compl etel y col l apsed.
Speci fi ed dry l ash i s 1.17 mm (0.046 i n.) for i ntake
and 1.28 mm (0.050 i n.) for exhaust. After performi ng
dry l ash check, refi l l adjuster wi th oi l and al l ow 10
mi nutes for adjuster/s to bl eed down before rotati ng
cam.
ENGINE MOUNT FRONT
REMOVAL
(1) Support the engi ne and transaxl e assembl y
wi th a fl oor jack so i t wi l l not rotate.
(2) Remove the front engi ne mount through bol t
from the i nsul ator and front crossmember mounti ng
bracket (Fi g. 22).
(3) Remove si x screws from ai r dam to al l ow
access to the front mount screws.
(4) Remove the front engi ne mount screws and
remove the i nsul ator assembl y.
(5) Remove the front mounti ng bracket, i f neces-
sary (Fi g. 22).
INSTALLATION
(1) Reverse removal procedure for i nstal l ati on and
ti ghten fasteners i n thi s order. For engi ne mount
Fig. 19 Refacing Valve Seats
Fig. 20 Checking Spring Installed Height and Valve
Tip Height Dimensions
Fig. 21 Valve Stem Oil Seal Special Tool C4745
adjustment procedure, refer to Adjustments, Engi ne
Mounts i n thi s Secti on.
(a) Ti ghten bol ts 2, 3 and 4 to 108 Nm (80 ft.
l bs.)
(b) Ti ghten bol ts 1 and 5 to 54 Nm (40 ft. l bs.).
(2) I nstal l si x screws to ai r dam and ti ghten to 12
Nm (105 i n. l bs.).
ENGINE MOUNT LEFT
REMOVAL
(1) Rai se vehi cl e on hoi st and remove l eft front
wheel .
(2) Support the transaxl e wi th a jack.
(3) Remove the i nsul ator through bol t from the
mount.
(4) Remove the transaxl e mount fasteners and
remove mount (Fi g. 23).
INSTALLATION
(1) Reverse removal procedure for i nstal l ati on.
(2) Ti ghten mount to transaxl e bol ts to 55 Nm (40
ft. l bs.)
(3) Ti ghten through bol t to 75 Nm (55 ft. l bs.)
(Fi g. 23).
(4) Engi ne mount adjustment, Refer to Engi ne
Mount Adjustment i n thi s secti on.
ENGINE MOUNT RIGHT
REMOVAL
NOTE: Right mount should only be serviced as an
assembly to prevent noise, vibration and harshness
concerns.
(1) Remove the purge duty sol enoi d and wi ri ng
harness from engi ne mount bracket.
(2) Remove the two ri ght engi ne mount i nsul ator
verti cal fasteners from frame rai l and l oosen the one
hori zontal fastener. Do not remove the large nut
located at the end of the core (Fig. 24).
(3) Remove the l oad on the engi ne mounts by
careful l y supporti ng the engi ne and transaxl e assem-
bl y wi th a fl oor jack.
(4) Remove the verti cal and hori zontal fasteners
from the engi ne si de bracket. Remove the mount
assembl y.
INSTALLATION
Ti ghten assembl y i n the fol l owi ng order:
a. Engi ne mount to rai l fasteners to 68 Nm (50 ft.
l bs.).
b. The verti cal engi ne fastener to 102 Nm (75 ft.
l bs.).
c. The hori zontal fastener to 150 Nm (111 ft. l bs.).
Fig. 22 Engine Mounting-Front
Fig. 23 Typical Engine MountingLeft
ENGINE MOUNT REAR
REMOVAL
(1) Rai se vehi cl e on hoi st and remove the l eft
front wheel .
(2) Support the transaxl e wi th a jack so i t wi l l not
rotate.
(3) Remove the i nsul ator thru bol t from the
mount and rear suspensi on crossmember.
(4) Remove the four mount fasteners and remove
the mount.
INSTALLATION
(1) Reverse the removal procedure for i nstal l ati on.
Refer to (Fi g. 25).
STRUCTURAL COLLAR
REMOVAL
(2) Remove front engi ne mounti ng bracket from
bendi ng strut and front i nsul ator mount.
(3) Remove bol ts attachi ng bendi ng strut to engi ne
and transaxl e.
(4) Remove bol ts attachi ng col l ar and strut to
engi ne, oi l pan, and transaxl e. Remove strut and col -
l ar.
INSTALLATION
CAUTION: Torque procedure for the structural col-
lar and bending strut must be followed or damage
could occur to oil pan, collar, and/or bending strut.
(1) Perform the fol l owi ng steps for i nstal l i ng struc-
tural col l ar and bendi ng strut. Refer to (Fi g. 26):
Step 1: Pl ace col l ar i nto posi ti on between tran-
saxl e and oi l pan. Hand start onl y, col l ar to transaxl e
bol t 1.
Step 2: I nstal l bol t 4, col l ar to oi l pan, hand
tight only.
Step 3: Posi ti on bendi ng strut i n pl ace and hand
start bol t 3 i nto the upper transaxl e hol e.
Step 4: I nstal l bol t 2, through strut and col l ar.
Hand starti ng onl y.
Step 5: I nstal l bol t 6, strut to cyl i nder bl ock,
hand tight only.
Step 6: I nstal l the remai ni ng col l ar to oi l pan
bol t 5, hand tight only.
Step 7: Fi nal torque col l ar to transaxl e bol ts 1
3, to 101 Nm (75 ft. l bs.)
Step 8: I nstal l bol ts 7 and 8, through strut and
i nto cyl i nder bl ock.
Step 9: Fi nal torque bol ts 4 8 to 61 Nm (45 ft.
l bs.).
Fig. 24 Engine MountingRight Side
Fig. 25 Engine MountingRear
Fig. 26 Structural Collar and Bending Strut
Removal and Installation
ENGINE ASSEMBLY
REMOVAL
(1) Perform fuel pressure rel ease procedure. Refer
to Group 14, Fuel System for procedure. Remove fuel
l i ne to fuel rai l .
(3) Remove Ai r cl eaner and hoses.
(4) Drai n cool i ng system. Refer to Group 7, Cool i ng
System for procedure.
(5) Remove upper radi ator hose and remove radi a-
tor fans. Refer to Group 7, Cool i ng System for proce-
dure.
(6) Remove l ower radi ator hose.
(7) Di sconnect automati c transmi ssi on cool er l i nes
and pl ug, i f equi pped.
(8) Di sconnect transmi ssi on shi ft l i nkage.
(9) Di sconnect throttl e body l i nkage.
(10) Di sconnect engi ne wi ri ng harness.
(11) Di sconnect heater hoses.
(12) Di scharge Ai r Condi ti oni ng System. Refer to
Group 24, Ai r Condi ti oni ng for procedure.
(13) Hoi st vehi cl e and remove ri ght i nner spl ash
shi el d. Remove wheel s and ti res.
(14) Loosen power steeri ng bel t for pump removal .
Refer to Group 7, Cool i ng System for procedure.
(15) Remove axl e shafts. Refer to Group 2, Suspen-
si on and Dri veshafts for procedure.
(16) Di sconnect exhaust pi pe from mani fol d.
(17) Remove front and rear engi ne mount brackets
from the body.
(18) Remove bendi ng braces and front engi ne
mount bracket. Remove transmi ssi on i nspecti on
cover.
(19) Mark fl expl ate to torque converter and
remove torque converter bol ts.
(20) I nstal l front engi ne mount bracket.
(22) Remove power steeri ng pump. Set pump
asi de.
(23) Remove A/C l i nes at compressor and cap.
(24) Remove ground straps to body.
(25) Rai se vehi cl e enough to al l ow engi ne dol l y
Speci al Tool 6135, cradl e Speci al Tool 6710 wi th
Posts Speci al Tool 6848 and Adaptor Speci al Tool
8130 to be i nstal l ed under vehi cl e (Fi g. 27).
(26) Loosen cradl e posts to al l ow movement for
proper posi ti oni ng. Locate two rear posts (ri ght si de
of engi ne) i nto the hol es on the engi ne bedpl ate.
Locate the two front posts (l eft si de of engi ne) on the
front engi ne bracket and A/C compressor bracket
(Fi g. 27). Lower vehi cl e and posi ti on cradl e mounts
unti l the engi ne i s resti ng on mounts. Ti ghten
mounts to cradl e frame. Thi s wi l l keep mounts from
movi ng when removi ng or i nstal l i ng engi ne and
transmi ssi on.
(27) Lower vehi cl e so the wei ght of ONLY THE
ENGINE AND TRANSMISSION are on the cradl e.
(28) Remove engi ne and transmi ssi on mount bol ts.
(29) Rai se vehi cl e sl owl y. I t may be necessary to
move the engi ne/transmi ssi on assembl y on the cradl e
to al l ow for removal around the body.
INSTALLATION
(1) Posi ti on engi ne and transmi ssi on assembl y
under vehi cl e and sl owl y l ower the vehi cl e over the
engi ne and transmi ssi on.
(2) Al i gn engi ne and transmi ssi on mounts to
attachi ng poi nts. I nstal l mounti ng bol ts at the ri ght
engi ne and l eft transmi ssi on mounts. Refer to proce-
dures outl i ned i n thi s secti on.
(3) Sl owl y rai se vehi cl e enough to remove the
engi ne dol l y and cradl e Speci al Tool s 6135 and 6710.
(4) I nstal l axl e shafts. Refer to Group 2, Suspen-
si on and Dri veshafts for procedure.
(5) I nstal l transmi ssi on and engi ne braces and
spl ash shi el ds.
(6) Connect exhaust system to mani fol d. Refer to
Group 11, Exhaust System and I ntake Mani fol d for
procedure and torque speci fi cati ons.
(7) I nstal l power steeri ng pump. Refer to Cool i ng
System Group 7, Accessory Dri ve Secti on for bel t ten-
si on adjustment.
(8) I nstal l A/C compressor hoses. Refer to Group
24, Heater and Ai r Condi ti oni ng for procedure.
(9) I nstal l accessory dri ve bel ts. Refer to Group 7,
Cool i ng System Accessory Dri ve Secti on for bel t ten-
si on adjustment.
(10) I nstal l front and rear engi ne mounts. Refer to
thi s secti on for procedure.
(11) I nstal l i nner spl ash shi el d. I nstal l wheel s and
ti res.
(12) Connect automati c transmi ssi on cool er l i nes,
and shi ft l i nkage. Refer to Group 21, Transmi ssi on
for procedures.
(13) Connect fuel l i ne and heater hoses.
(14) I nstal l ground straps. Connect engi ne and
throttl e body connecti ons and harnesses. Refer to
Group 8, El ectri cal for procedure.
(15) Connect throttl e body l i nkage. Refer to Group
14, Fuel System for procedure.
(16) I nstal l radi ator fans. I nstal l radi ator hoses.
Fi l l cool i ng system. Refer to Group 7, Cool i ng System
for fi l l i ng procedure.
(17) Connect battery.
(18) I nstal l ai r cl eaner and hoses.
(19) I nstal l oi l fi l ter. Fi l l engi ne crankcase wi th
proper oi l to correct l evel .
(20) Start engi ne and run unti l operati ng temper-
ature i s reached.
(21) Adjust transmi ssi on l i nkage, i f necessary.
Fig. 27 Positioning Engine Cradle Support Post MountsTypical
CYLINDER HEAD COVER
REMOVAL
(1) Remove upper i ntake mani fol d. Refer to Group
11, Exhaust System and I ntake Mani fol d.
(2) Remove nuts attachi ng front and rear i ntake
mani fol d supports from cyl i nder head cover attachi ng
studs.
(3) Remove i gni ti on coi l pack and pl ug wi res (Fi g.
28). Remove ground strap.
(4) Remove the cyl i nder head cover fasteners.
(5) Remove cyl i nder head cover from cyl i nder
head.
INSTALLATION
NOTE: Replace spark plug well seals when install-
ing a new cylinder head cover gasket.
(1) Cl ean al l seal i ng surfaces.
(2) I nstal l new cyl i nder head cover gaskets and
spark pl ug seal s (Fi g. 29).
CAUTION: Do not allow oil or solvents to contact
the timing belt as they can deteriorate the rubber
and cause tooth skipping.
(3) Appl y Mopar Si l i cone Rubber Adhesi ve Seal -
ant at the camshaft cap corners and at the top edge
of the 1/2 round seal .
(4) I nstal l cyl i nder head cover assembl y to head
and ti ghten fasteners i n sequence shown i n (Fi g. 30).
Usi ng the 3 step torque method:
(a) Ti ghten al l fasteners to 4.5 Nm (40 i n. l bs.)
(b) Ti ghten al l fasteners to 9.0 Nm (80 i n. l bs.)
(c) Ti ghten al l fasteners to 12 Nm (105 i n. l bs.)
(5) I nstal l i gni ti on coi l pack and pl ug wi res.
Ti ghten fasteners to 12 Nm (105 i n. l bs.).
(6) I nstal l ground strap.
(7) I nstal l front and rear i ntake mani fol d support
brackets and attachi ng nuts, but do not ti ghten at
thi s ti me.
(8) I nstal l upper i ntake mani fol d. Refer to Group
11, Exhaust System and I ntake Mani fol d for proce-
dure.
(9) Fi nal torque i ntake mani fol d support nuts to
28 Nm (250 i n. l bs.).
CAMSHAFT
REMOVAL
(1) Remove cyl i nder head cover usi ng procedure
outl i ned i n thi s secti on.
(2) Remove ti mi ng bel t, sprockets and covers.
Refer to Ti mi ng Bel t Servi ce outl i ned i n thi s secti on.
(3) Beari ng caps are i denti fi ed for l ocati on.
Remove the outsi de beari ng caps fi rst (Fi g. 31).
(4) Loosen the camshaft beari ng cap attachi ng
fasteners i n sequence shown (Fi g. 32) one camshaft
at a ti me.
CAUTION: Camshafts are not interchangeable. The
intake cam number 6 thrust bearing face spacing is
wider.
Fig. 28 Ignition Coil Pack and Ground Strap
Fig. 29 Cylinder Head Cover Gasket and Spark Plug
Seals
Fig. 30 Cylinder Head Cover Tightening Sequence
(5) I denti fy the camshafts before removi ng from
the head. The camshafts are not i nterchangeabl e.
CAMSHAFT END PLAY
(1) Oi l camshaft journal s and i nstal l camshaft
WITHOUT cam fol l ower assembl i es. I nstal l rear cam
caps and ti ghten screws to speci fi ed torque.
(2) Usi ng a sui tabl e tool , move camshaft as far
rearward as i t wi l l go.
(3) Zero di al i ndi cator (Fi g. 33).
(4) Move camshaft as far forward as i t wi l l go.
(5) End pl ay travel : 0.050.15 mm (0.0020.010
i n.).
(6) I f end pl ay i s excessi ve check cyl i nder head
and camshaft for wear; repl ace as necessary.
INSTALLATION
CAUTION: Ensure that NONE of the pistons are at
top dead center when installing the camshafts.
(1) Remove camshaft retai ni ng caps and l ubri cate
beari ng journal s. I nstal l cam fol l owers and camshafts
wi th cl ean oi l . I nstal l ri ght and l eft camshaft beari ng
caps #2 thru #5 and ri ght #6. Ti ghten M6 fasteners
to 12 Nm (105 i n. l bs.) i n sequence shown i n (Fi g.
34).
(2) Appl y Mopar Gasket Maker to No. 1 and No.
6 beari ng caps (Fi g. 35). I nstal l beari ng caps and
ti ghten M8 fasteners to 28 Nm (250 i n. l bs.).
(3) Beari ng end caps must be i nstal l ed before
seal s can be i nstal l ed.
(4) I nstal l ti mi ng bel t, sprockets and covers. Refer
to ti mi ng bel t servi ce outl i ned i n thi s secti on.
(5) I nstal l cyl i nder head cover usi ng procedure
Fig. 31 Camshaft Bearing Cap Identification
Fig. 32 Camshaft Bearing Cap Removal
Fig. 33 Camshaft End Play
Fig. 34 Camshaft Bearing Cap Tightening Sequence
CAMSHAFT FOLLOWER
REMOVAL
(2) Remove ti mi ng bel t, sprockets and covers
usi ng procedure outl i ned i n thi s secti on.
(3) Remove camshaft. Refer to procedure previ -
ousl y outl i ne thi s secti on.
(4) Remove cam fol l ower assembl i es from cyl i nder
head. Keep the cam fol l owers i n the order they have
been removed from the head for reassembl y.
I NSPECTI ON
I nspect the cam fol l ower assembl y for wear or
damage (Fi g. 36). Repl ace as necessary.
INSTALLATION
(1) Lubri cate wi th cl ean oi l and i nstal l cam fol -
l ower assembl i es i n thei r ori gi nal posi ti on on the
hydraul i c adjuster and val ve stem (Fi g. 37).
(2) I nstal l the camshafts. Refer to procedure pre-
vi ousl y outl i ned i n thi s secti on.
(3) I nstal l ti mi ng bel t, sprockets and covers usi ng
procedure outl i ned i n thi s secti on.
(4) I nstal l cyl i nder head cover usi ng procedure out-
BALANCE SHAFTS CARRIER ASSEMBLY
BALANCE SHAFTS
REMOVAL
Refer to Ti mi ng Bel t Cover, and Ti mi ng Bel t
removal procedure i n thi s secti on. To repai r bal ance
shafts carri er assembl y.
(1) Remove chai n cover, gui de and tensi oner (Fi g.
38). Al so see Carri er Assembl y Removal for servi ce
procedures requi ri ng onl y temporary rel ocati on of
assembl y.
(2) Remove gear cover retai ni ng stud (doubl e
ended to al so retai n chai n gui de). Remove cover and
bal ance shaft gears (Fi g. 38).
Fig. 35 Camshaft Bearing Cap Sealing
Fig. 36 Cam Follower Assembly
Fig. 37 Cam Follower AssembliesInstallation
Fig. 38 Chain Cover, Guide and Tensioner
(3) Remove bal ance shaft gear and chai n sprocket
retai ni ng screws and crankshaft chai n sprocket.
Remove chai n and sprocket assembl y (Fi g. 39). Usi ng
two wi de pry bars, work the sprocket back and forth
unti l i t i s off the shaft.
(4) Remove carri er gear cover and bal ance shafts
(Fi g. 40).
(5) Remove four carri er to crankcase attachi ng
bol ts to separate carri er from engi ne bedpl ate.
BALANCE SHAFT CARRIER
REMOVAL
The fol l owi ng components wi l l remai n i ntact dur-
i ng carri er removal . Gear cover, gears, bal ance shafts
and the rear cover (Fi g. 41).
(1) Remove chai n cover and dri ven bal ance shaft
chai n sprocket screw.
(2) Loosen tensi oner pi vot and adjusti ng screws,
move dri ven bal ance shaft i nboard through dri ven
chai n sprocket. Sprocket wi l l hang i n l ower chai n
l oop.
(3) Remove carri er to crankcase attachi ng bol ts to
remove carri er.
BALANCE SHAFT INSTALLATION
Bal ance shaft and carri er assembl y i nstal l ati on i s
the reverse of the removal procedure. During instal-
lation crankshaft to balance shaft timing must
be established. Refer to Timing procedure out-
lined in this section.
BALANCE SHAFT TIMING
(1) Wi th bal ance shafts i nstal l ed i n carri er (Fi g.
42) posi ti on carri er on crankcase and i nstal l four
attachi ng bol ts and ti ghten to 54 Nm (40 ft. l bs.).
(2) Turn bal ance shafts unti l both shaft key ways
are up Paral l el to verti cal centerl i ne of engi ne.
I nstal l short hub dri ve gear on sprocket dri ven shaft
and l ong hub gear on gear dri ven shaft. After i nstal -
l ati on gear and bal ance shaft keyways must be up
wi th gear ti mi ng marks meshed as shown i n (Fi g.
43).
Fig. 39 Drive Chain and Sprockets
Fig. 40 Gear Cover and Gears
Fig. 41 Balance Shaft(s)Removal/Installation
(3) I nstal l gear cover and ti ghten doubl e ended
stud/washer fastener to 12 Nm (105 i n. l bs.).
(4) I nstal l crankshaft sprocket usi ng Speci al Tool
6052 (Fi g. 44).
(5) Turn crankshaft unti l number one cyl i nder i s
at Top Dead Center (TDC). The ti mi ng marks on the
chai n sprocket shoul d l i ne up wi th the parti ng l i ne
on the l eft si de of number one mai n beari ng cap.
(Fi g. 45).
(6) Pl ace chai n over crankshaft sprocket so that
the ni ckel pl ated l i nk of the chai n i s over the number
1 cyl i nder ti mi ng mark on the crankshaft sprocket
(Fi g. 45).
(7) Pl ace bal ance shaft sprocket i nto the ti mi ng
chai n (Fi g. 45) so that the ti mi ng mark on the
sprocket (yel l ow dot) mates wi th the (l ower) ni ckel
pl ated l i nk on the chai n
(8) Wi th bal ance shaft keyways poi nti ng up (12
ocl ock) sl i de the bal ance shaft sprocket onto the nose
of the bal ance shaft. The bal ance shaft may have to
be pushed i n sl i ghtl y to al l ow for cl earance.
Fig. 42 Balance Shaft(s)Removal/Installation
Fig. 43 Gear Timing
Fig. 44 Crankshaft SprocketInstallation
Fig. 45 Balance Shaft Timing
NOTE: THE TIMING MARK ON THE SPROCKET,
THE (LOWER) NICKEL PLATED LINK, AND THE
ARROW ON THE SIDE OF THE GEAR COVER
SHOULD LINE UP WHEN THE BALANCE SHAFTS
ARE TIMED CORRECTLY.
(9) I f the sprockets are ti med correctl y i nstal l the
bal ance shaft bol ts and ti ghten to 28 Nm (250 i n.
l bs.). A wood bl ock pl aced between crankcase and
crankshaft counterbal ance wi l l prevent crankshaft
and gear rotati on.
CHAIN TENSIONING
(1) I nstal l chai n tensi oner l oosel y assembl ed.
(2) Posi ti on gui de on doubl e ended stud maki ng
sure tab on the gui de fi ts i nto sl ot on the gear cover.
I nstal l and ti ghten nut/washer assembl y to 12 Nm
(105 i n. l bs.).
(3) Pl ace a shi m 1 mm (0.039 i n.) thi ck x 70 mm
(2.75 i n.) l ong or between tensi oner and chai n. Push
tensi oner and shi m up agai nst the chai n. Apply firm
pressure (5.5 to 6.6 lbs.) directly behind the
adjustment slot to take up all slack. Chai n must
have shoe radi us contact as shown i n (Fi g. 46).
(4) Wi th the l oad appl i ed, ti ghten top tensi oner
bol t fi rst, then bottom pi vot bol t. Ti ghten bol ts to 12
Nm (105 i n. l bs.). Remove shi m.
(5) I nstal l carri er covers and ti ghten screws to 12
Nm (105 i n. l bs.).
HYDRAULIC LASH ADJUSTER
REMOVAL
(1) Remove cyl i nder head cover. Refer to procedure
(2) Remove cam fol l ower assembl y. Refer to cam-
shaft removal procedure outl i ned i n thi s secti on to
gai n access to cam fol l owers and l ash adjusters.
(3) Mark hydraul i c l ash adjusters for reassembl y
i n thei r ori gi nal posi ti on. Lash adjusters are servi ced
as an assembl y.
INSTALLATION
(1) I nstal l hydraul i c l ash adjuster assembl y mak-
i ng sure adjusters are at l east parti al l y ful l of oi l .
Thi s i s i ndi cated by l i ttl e or no pl unger travel when
the l ash adjuster i s depressed.
(2) I nstal l cam fol l ower assembl y as previ ousl y
(3) I nstal l camshaft as previ ousl y outl i ned i n thi s
secti on.
(4) I nstal l cyl i nder head cover as previ ousl y out-
VALVE SPRINGS AND VALVE SEALS IN VEHICLE
REMOVAL
(1) Remove camshafts as previ ousl y outl i ned i n
thi s secti on.
(2) Rotate crankshaft unti l pi ston i s at TDC on
compressi on.
(3) Wi th ai r hose attached to adapter tool
i nstal l ed i n spark pl ug hol e, appl y 90-120 psi ai r
pressure.
(4) Usi ng Speci al Tool MD-998772-A wi th adapter
6779 (Fi g. 47) compress val ve spri ngs and remove
val ve l ocks.
(5) Remove val ve spri ng.
(6) Remove val ve stem seal by a usi ng val ve stem
seal tool .
INSTALLATION
(1) I nstal l val ve seal /val ve spri ng seat assembl y
(Fi g. 48). Push the assembl y down to seat i t onto the
val ve gui de.
(2) I nstal l val ve spri ng and retai ner, use Speci al
Tool MD-998772-A wi th adapter 6779 to compress
val ve spri ngs onl y enough to i nstal l l ocks (Fi g. 47).
Correct al i gnment of tool i s necessary to avoi d ni ck-
i ng val ve stems.
(3) Remove ai r hose and i nstal l spark pl ugs.
(4) I nstal l camshafts as previ ousl y outl i ned i n thi s
secti on.
(5) I nstal l cyl i nder head cover as previ ousl y out-
Fig. 46 Chain Tension Adjustment
CYLINDER HEAD
REMOVAL
(1) Perform fuel system pressure rel ease proce-
dure before attempting any repairs. Refer to
Group 14, Fuel System for procedure.
(2) Di sconnect negati ve battery cabl e. Drai n cool -
i ng system. Refer to Group 7, Cool i ng System for pro-
cedure.
(3) Remove ai r cl eaner and di sconnect al l vacuum
l i nes, el ectri cal wi ri ng and fuel l i nes from throttl e
body.
(4) Remove throttl e l i nkage. Refer to Group 14,
Fuel System for procedures
(5) Remove accessory dri ve bel ts. Refer to Group
7, Cool i ng System for procedure.
(6) Remove power brake vacuum hose from i ntake
mani fol d.
(7) Rai se vehi cl e and remove exhaust pi pe from
mani fol d.
(8) Remove power steeri ng pump assembl y and
set asi de.
(9) Di sconnect coi l pack wi ri ng connector and
remove coi l pack and pl ug wi res from engi ne.
(10) Remove cam sensor and fuel i njectors wi ri ng
connectors.
(11) Remove ti mi ng bel t and camshaft sprocket.
Refer to procedure outl i ned i n thi s secti on.
(12) Remove ti mi ng bel t i dl er pul l ey and rear ti m-
i ng bel t cover.
(14) Remove camshafts and cam fol l owers. Refer to
procedures outl i ned i n thi s secti on for procedures.
(15) Remove cyl i nder head bol ts and remove cyl -
i nder head from engi ne bl ock.
(16) I nspect and cl ean cyl i nder head. Refer to
Cl eani ng and I nspecti on outl i ned i n thi s secti on for
procedures.
INSTALLATION
NOTE: The Cylinder head bolts should be exam-
ined BEFORE reuse. If the threads are necked
down, the bolts should be replaced (Fig. 49).
Necki ng can be checked by hol di ng a scal e or
strai ght edge agai nst the threads. I f al l the threads
do not contact the scal e the bol t shoul d be repl aced.
(1) Before i nstal l i ng the bol ts, the threads shoul d
be coated wi th engi ne oi l .
(2) Ti ghten the cyl i nder head bol ts i n the
sequence shown i n (Fi g. 50). Usi ng the 4 step torque
turn method, ti ghten accordi ng to the fol l owi ng val -
ues:
Fi rst Al l to 34 Nm (25 ft. l bs.)
Second Al l to 68 Nm (50 ft. l bs.)
Thi rd Al l to 68 Nm (50 ft. l bs.)
CAUTION: Do not use a torque wrench for the fol-
lowing step.
Fourth Turn an addi ti onal 1/4 Turn,
(3) I nstal l camshafts and cam fol l owers. Refer to
procedures outl i ned i n thi s secti on for procedures.
Fig. 47 Valve SpringRemoval/Installation
Fig. 48 Valve Stem Seal/Valve Spring Seat
Fig. 49 Checking Bolts for Stretching (Necking)
(4) I nstal l cyl i nder head cover usi ng procedure out-
(5) I nstal l rear ti mi ng bel t cover and ti mi ng bel t
i dl er pul l ey.
(6) I nstal l ti mi ng bel t and camshaft sprocket.
(7) I nstal l cam sensor and fuel i njectors wi ri ng
connectors.
(8) I nstal l coi l pack and pl ug wi res onto the
engi ne. Connect coi l pack wi ri ng connector.
(9) I nstal l power steeri ng pump assembl y.
(10) Rai se vehi cl e and i nstal l the exhaust pi pe to
the mani fol d.
(11) I nstal l power brake vacuum hose to the i ntake
mani fol d.
Cool i ng System for procedure.
(13) I nstal l throttl e l i nkage. Refer to Group 14,
Fuel System for procedures.
(14) I nstal l ai r cl eaner and connect al l vacuum
l i nes, el ectri cal wi ri ng and fuel l i nes to the throttl e
body.
System for procedure. Connect negati ve battery
cabl e.
VALVES AND VALVE SPRINGS
REMOVAL
spri ngs usi ng a uni versal val ve spri ng compressor.
(4) I nspect and cl ean the val ves. Refer to Cl eani ng
and I nspecti on outl i ned i n thi s secti on for procedure.
INSTALLATION
(2) I nstal l new val ve stem seal s on al l val ves
usi ng a val ve stem seal tool (Fi g. 51). The val ve stem
seal s shoul d be pushed fi rml y and squarel y over
val ve gui de.
CAUTION: When oversize valves are used, the cor-
responding oversize valve seal must also be used.
Excessive guide wear may result if oversize seals
are not used with oversize valves.
can become dislocated. Ensure both locks are in
the correct location after removing tool.
than 38.75 mm (1.525 i n.), i nstal l a .762 mm (0.030
i n.) spacer under the val ve spri ng seat to bri ng
Fig. 50 Cylinder Head Tightening Sequence
Fig. 51 Valve Stem Oil Seal Tool
VIBRATION DAMPER
REMOVAL
Remove crankshaft vi brati on damper bol t. Remove
damper by usi ng Speci al Tool 1026 and I nsert
6827A (Fi g. 53).
INSTALLATION
I nstal l crankshaft vi brati on damper usi ng M12
1.75 x 150 mm bol t, washer, thrust beari ng and nut
from Speci al Tool 6792. I nstal l crankshaft vi brati on
damper bol t and ti ghten to 142 Nm (105 ft. l bs.)
(Fi g. 54).
Fig. 52 Checking Spring Installed Height and Valve
Tip Height Dimensions
Fig. 53 Crankshaft Vibration DamperRemoval
Fig. 54 Crankshaft Vibration DamperInstallation
TIMING BELT COVER
FRONT COVER
REMOVAL
(1) Remove crankshaft damper. Refer to crank-
shaft damper removal for procedure.
(2) Remove front ti mi ng bel t cover fasteners (Fi g.
55) and remove covers.
INSTALLATION
(1) I nstal l front ti mi ng bel t covers (Fi g. 55).
Ti ghten bol ts to 4.5 Nm (40 i n. l bs.).
(2) I nstal l crankshaft damper. Refer to crankshaft
damper i nstal l ati on for procedure.
REAR COVER
REMOVAL
(1) Remove front covers.
(2) Remove engi ne mount bracket (Fi g. 55).
(3) Remove Ti mi ng Bel t, I dl er Pul l ey, and Cam-
shaft Sprockets. Refer to procedure outl i ned i n thi s
secti on.
(4) Remove rear cover fasteners and remove cover
from engi ne (Fi g. 56).
INSTALLATION
(1) I nstal l rear ti mi ng bel t cover and fasteners
(Fi g. 56).
(2) I nstal l camshaft sprockets. Whi l e hol di ng
sprocket wi th Speci al Tool s C-4687 and C-4687-1,
ti ghten center bol t to 101 Nm (75 ft. l bs.).
(3) I nstal l ti mi ng bel t i dl er pul l ey and ti ghten
(4) I nstal l Ti mi ng Bel t. Refer to procedure outl i ned
i n thi s secti on.
(5) I nstal l engi ne mount bracket and ti ghten bol ts
to 61 Nm (45 ft. l bs.).
(6) I nstal l front covers.
TIMING BELT
REMOVAL
(1) Rai se vehi cl e on hoi st. Remove ri ght front
wheel .
(2) Remove ri ght i nner spl ash shi el d.
(3) Remove accessory dri ve bel ts. Refer to Group 7,
Cool i ng System.
(4) Remove crankshaft damper bol t, and remove
damper. Refer to Removal and I nstal l ati on procedure
i n thi s secti on.
(5) Remove l ower ti mi ng bel t cover fasteners and
remove cover (Fi g. 57).
Fig. 55 Front Timing Belt Cover
Fig. 56 Rear Timing Belt Cover Fasteners
(6) Lower vehi cl e and remove upper ti mi ng bel t
cover fasteners and remove cover.
(7) Remove ri ght engi ne mount and support
bracket. Refer to Removal and I nstal l ati on procedure
i n thi s secti on.
CAUTION: When aligning crankshaft and camshaft
timing marks always rotate engine from crankshaft.
Camshaft should not be rotated after timing belt is
removed. Damage to valve components may occur.
Always align timing marks before removing timing
belt.
(8) Before the removal of the ti mi ng bel t, rotate
crankshaft unti l TDC mark on oi l pump housi ng
al i gns wi th TDC mark on crankshaft sprocket (trai l -
i ng edge of sprocket tooth) (Fi g. 58).
NOTE: The crankshaft sprocket mark is located on
the trailing edge of the sprocket tooth. Failure to
align trailing edge of sprocket tooth to mark on oil
pump housing will cause the camshaft marks to be
misaligned (Fig. 58).
(9) I nstal l 6 mm Al l en wrench i nto bel t tensi oner.
Before rotati ng the tensi oner i nsert the l ong end of a
1/8 or 3 mm Al l en wrench i nto the pi n hol e on the
front of the tensi oner (Fi g. 59). Whi l e rotati ng the
tensi oner countercl ockwi se push i n l i ghtl y on the 1/8
or 3 mm Al l en wrench, unti l i t sl i des i nto the l ocki ng
hol e.
Fig. 57 Timing Belt Covers
Fig. 58 Crankshaft and Camshaft Timing
Fig. 59 Locking Timing Belt Tensioner
CAUTION: If timing belt was damaged due to incor-
rect tracking (alignment), the belt tensioner assem-
bly must be replace. Refer to Timing Belt Tensioner
Assembly Removal and Installation procedure out-
lined in this section.
INSTALLATION
(1) Set crankshaft sprocket to TDC by al i gni ng
the sprocket wi th the arrow on the oi l pump housi ng.
(2) Set camshafts ti mi ng marks so that the
exhaust camshaft sprocket i s a 1/2 notch bel ow the
i ntake camshaft sprocket (Fi g. 61).
CAUTION: Ensure that the arrows on both cam-
shaft sprockets are facing up.
(3) I nstal l ti mi ng bel t. Starti ng at the crankshaft,
go around the water pump sprocket, i dl er pul l ey,
camshaft sprockets and then around the tensi oner
(Fi g. 62).
(4) Move the exhaust camshaft sprocket counter-
cl ockwi se (Fi g. 62) to al i gn marks and take up bel t
sl ack.
NOTE: A new tensioner is held in the wound posi-
tion by a pull pin.
(5) Remove the pul l pi n or Al l en wrench from the
bel t tensi oner.
(6) Once ti mi ng bel t has been i nstal l ed and ten-
si oner rel eased, rotate crankshaft two (2) compl ete
revol uti ons. Veri fy that the TDC marks on crank-
shaft and ti mi ng marks on the camshafts are al i gned
as shown i n (Fi g. 60).
(7) I nstal l ri ght engi ne mount and support
bracket. Refer to Removal and I nstal l ati on procedure
i n thi s secti on.
(8) I nstal l upper ti mi ng bel t cover bol ts 4.5 Nm
(40 i n. l bs.).
(9) I nstal l the l ower ti mi ng bel t cover bol ts 4.5
Nm (40 i n. l bs.).
(10) I nstal l crankshaft damper. Refer to procedure
Cool i ng System.
(12) I nstal l ri ght i nner spl ash shi el d.
(13) I nstal l ri ght front wheel .
Fig. 61 Camshaft Sprocket Alignment
TIMING BELT TENSIONER ASSEMBLY
REMOVAL
(1) Remove ti mi ng bel t. Refer to Removal and
I nstal l ati on procedure i n thi s secti on.
(2) Remove ti mi ng bel t i dl er pul l ey.
(3) Hol d camshaft sprocket wi th Speci al Tool s
C-4687 and C-4687-1 Adapter, whi l e removi ng bol t
(Fi g. 63). Remove both cam sprockets.
(4) Remove rear ti mi ng bel t cover fasteners and
remove cover from engi ne (Fi g. 64).
(5) Remove l ower bol t attachi ng ti mi ng bel t ten-
si oner assembl y to engi ne and remove tensi oner as
an assembly (Fi g. 65).
INSTALLATION
(1) Al i gn ti mi ng bel t tensi oner assembl y to engi ne
and i nstal l l ower mounti ng bol t but do not tighten
(Fi g. 65). To properl y al i gn tensi oner assembl yi n-
stal l one of the engi ne bracket mounti ng bol ts (M10)
5 to 7 turns i nto the tensi oners upper mounti ng l oca-
ti on (Fi g. 65).
(2) Torque the tensi oners l ower mounti ng bol t to
61 Nm (45 ft. l bs.). Remove the upper bol t used for
tensi oner al i gnment.
(3) I nstal l rear ti mi ng bel t cover and fasteners.
(4) I nstal l ti mi ng bel t i dl er pul l ey and ti ghten
(5) I nstal l camshaft sprockets. Use Speci al Tool s
C-4687 and C-4687-1 Adapter to hol d camshaft
sprockets (Fi g. 63) and ti ghten attachi ng bol ts to 101
Nm (75 ft. l bs.).
(6) I nstal l ti mi ng bel t. Refer to procedure outl i ned
i n thi s secti on.
Fig. 62 Timing BeltInstallation
Fig. 63 Camshaft SprocketsRemoval/Installation
Fig. 64 Rear Timing Belt Cover Fasteners
CAMSHAFT OIL SEAL FRONT
REMOVAL
(1) Remove front ti mi ng bel t covers and ti mi ng
bel t. Refer to procedures outl i ned i n thi s secti on.
(2) Hol d camshaft sprocket wi th Speci al Tool s
C-4687 and 4687-1 whi l e removi ng center bol t (Fi g.
66).
(3) Remove camshaft seal usi ng Speci al Tool
C-4679-A (Fi g. 67).
CAUTION: Do not nick shaft seal surface or seal
bore
INSTALLATION
(1) Shaft seal surface must be free of varni sh, di rt
or ni cks. Pol i sh wi th 400 gri t paper i f necessary.
(2) I nstal l camshaft seal i nto cyl i nder head usi ng
Speci al Tool MD-998306 unti l fl ush wi th head (Fi g.
68).
(3) I nstal l camshaft sprocket. Whi l e hol di ng
sprocket wi th Speci al Tool s C-4687 and 4687-1,
ti ghten center bol t to 101 Nm (75 ft. l bs.) (Fi g. 66).
Fig. 65 Timing Belt Tensioner AssemblyRemoval/
Installation
Fig. 66 Camshaft SprocketRemoval/Installation
Fig. 67 Camshaft Oil SealRemoval With C-4679A
Fig. 68 Camshaft SealInstallation
CRANKSHAFT OIL SEAL FRONT
REMOVAL
(1) Usi ng Speci al Tool 1026 and I nsert 6827-A,
remove crankshaft damper (Fi g. 69).
(2) Remove outer ti mi ng bel t cover and ti mi ng
bel t. Refer to procedures outl i ned i n thi s secti on.
(3) Remove crankshaft sprocket usi ng Speci al Tool
6793 and i nsert C-4685-C2 (Fi g. 70).
bore.
(4) Usi ng Tool 6771 to remove front crankshaft oi l
seal (Fi g. 71). Be careful not to damage the seal sur-
face of cover.
INSTALLATION
(1) I nstal l new seal by usi ng Tool 6780 (Fi g. 72).
(2) Pl ace seal i nto openi ng wi th seal spri ng
towards the i nsi de of engi ne. I nstal l seal unti l fl ush
wi th cover.
(3) I nstal l crankshaft sprocket (Fi g. 73). Usi ng
Speci al Tool 6792.
(4) I nstal l ti mi ng bel t and ti mi ng bel t covers. Refer
to Ti mi ng System Secti on for ti mi ng bel t covers and
bel t.
(5) I nstal l crankshaft damper (Fi g. 74). Use thrust
beari ng/washer and 12M 1.75 x 150 mm bol t from
Speci al Tool 6792. I nstal l crankshaft damper bol t and
ti ghten to 142 Nm (105 ft. l bs.)
Fig. 69 Crankshaft DamperRemoval
Fig. 70 Crankshaft SprocketRemoval
Fig. 71 Front Crankshaft Oil SealRemoval
Fig. 72 Front Crankshaft Oil SealInstallation
CRANKSHAFT OIL SEAL REAR
REMOVAL
(1) I nsert a 3/16 fl at bl aded screwdri ver between
the dust l i p and the metal case of the crankshaft
seal . Angl e the screwdri ver (Fi g. 75) through the dust
l i p agai nst metal case of the seal . Pry out seal .
CAUTION: Do not permit the screwdriver blade to
contact crankshaft seal surface. Contact of the
screwdriver blade against crankshaft edge (cham-
fer) is permitted.
Fig. 74 Crankshaft DamperInstallation
Fig. 75 Rear Crankshaft Oil SealRemoval
INSTALLATION
CAUTION: If burr or scratch is present on the
crankshaft edge (chamfer), cleanup with 400 grit
sand paper to prevent seal damage during installa-
tion of new seal.
NOTE: When installing seal, no lube on seal is
needed.
(1) Pl ace Speci al Tool 6926-1 on crankshaft. Thi s i s
a pi l ot tool wi th a magneti c base (Fi g. 76).
(2) Posi ti on seal over pi l ot tool . Make sure you can
read the words THIS SIDE OUT on seal (Fi g. 76).
Pi l ot tool shoul d remai n on crankshaft duri ng i nstal -
l ati on of seal . Ensure that the l i p of the seal i s faci ng
towards the crankcase duri ng i nstal l ati on.
CAUTION: If the seal is driven into the block past
flush, this may cause an oil leak.
(3) Dri ve the seal i nto the bl ock usi ng Speci al Tool
6926-2 and handl e C-4171 (Fi g. 77) unti l the tool bot-
toms out agai nst the bl ock (Fi g. 78).
Fig. 76 Rear Crankshaft Seal and Special Tool
6926-1
Fig. 77 Crankshaft Seal Special Tool 6926-2
Fig. 78 Rear Crankshaft SealInstallation
OIL PAN
REMOVAL
(1) Rai se vehi cl e on hoi st and drai n engi ne oi l .
(2) Remove front engi ne mount bracket from
engi ne and i nsul ator mount.
(3) Remove bol ts attachi ng bendi ng strut to engi ne
and transaxl e.
(4) Remove bol ts attachi ng col l ar and bendi ng
strut to engi ne, oi l pan, and transaxl e (Fi g. 79).
Remove strut and col l ar.
(5) Remove oi l pan.
(6) Cl ean oi l pan and al l gasket surfaces.
INSTALLATION
(1) Appl y Mopar Si l i cone Rubber Adhesi ve Seal -
ant or equi val ent at the oi l pump to engi ne bl ock
parti ng l i ne (Fi g. 80).
(2) I nstal l the oi l pan gasket to the bl ock (Fi g.
81).
(3) I nstal l pan and ti ghten the screws to 12 Nm
(105 i n. l bs.).
CAUTION: Torque procedure for the structural col-
lar and bending strut must be followed or damage
could occur to oil pan, collar, and/or bending strut.
(4) Perform the fol l owi ng steps for i nstal l i ng struc-
tural col l ar and bendi ng strut. Refer to (Fi g. 79):
Step 1: Pl ace col l ar i nto posi ti on between tran-
saxl e and oi l pan. Hand start onl y, col l ar to transaxl e
bol t 1.
Step 2: I nstal l bol t 4, col l ar to oi l pan, hand
tight only.
Step 3: Posi ti on bendi ng strut i n pl ace and hand
start bol t 3 i nto the upper transaxl e hol e.
Step 4: I nstal l bol t 2, through strut and col l ar.
Hand starti ng onl y.
Step 5: I nstal l bol t 6, strut to cyl i nder bl ock,
hand tight only.
Step 6: I nstal l the remai ni ng col l ar to oi l pan
bol t 5, hand tight only.
Step 7: Fi nal torque col l ar to transaxl e bol ts 1
3, to 101 Nm (75 ft. l bs.)
Step 8: I nstal l bol ts 7 and 8, through strut and
i nto cyl i nder bl ock.
Step 9: Fi nal torque bol ts 4 8 to 61 Nm (45 ft.
l bs.).
(5) I nstal l front mount bracket to engi ne and front
i nsul ator. Refer to procedure i n the secti on.
(6) Lower vehi cl e and fi l l engi ne crankcase wi th
Fig. 79 Structural Collar and Bending Strut
Removal and Installation
Fig. 80 Oil Pan Sealing
Fig. 81 Oil Pan Gasket Installation
CRANKSHAFT
REMOVAL
NOTE: Crankshaft can not be removed when
engine is in vehicle.
(1) Remove oi l fi l ter and oi l pan. Refer to proce-
dure outl i ned i n thi s secti on.
(2) Remove Ti mi ng Bel t Cover, Ti mi ng Bel t and
Oi l Pump. Refer to procedure outl i ned i n thi s secti on.
(3) Remove Bal ance Shafts Assembl y. Refer to pro-
cedure outl i ned i n thi s secti on.
(4) Remove al l mai n beari ng cap bedpl ate bol ts
from the engi ne bl ock. Refer to procedure outl i ned i n
thi s secti on.
(5) Usi ng a mal l et gentl y tap the bedpl ate l oose
from the engi ne bl ock dowel pi ns.
CAUTION: Do not pry up on one side of the bed-
plate. Damage may occur to cylinder block to bed-
plate alignment and thrust bearing.
(6) Bedpl ate shoul d be removed evenl y from the
cyl i nder bl ock dowel pi ns to prevent damage to the
dowel pi ns and thrust beari ng.
(7) Li ft out crankshaft from cyl i nder bl ock. Do not
damage the mai n beari ngs or journal s when remov-
i ng the crankshaft.
INSTALLATION
cati on groove i n the cyl i nder bl ock (Fi g. 82).
hol e i n beari ngs and beari ng tabs seat i n the bl ock
tab sl ots.
CAUTION: Do not get oil on the bedplate mating
surface. It will may effect the sealer ability to seal
the bedplate to cylinder block.
(3) Oi l the beari ngs and journal s. I nstal l crank-
shaft.
engine.
(4) Appl y 1.5 to 2.0 mm (0.059 to 0.078 i n.) bead of
Mopar Torque Cure Gasket Maker to cyl i nder bl ock
(6) Before i nstal l i ng the bol ts the threads shoul d
be oi l ed wi th cl ean engi ne oi l , wi pe off any excess oi l .
Sequence
bol ts 11, 17 and 20 fi nger ti ght. Ti ghten these bol ts
der bl ock.
(8) To ensure correct thrust beari ng al i gnment per-
form the fol l owi ng steps:
Step 1: Rotate crankshaft unti l number 4 pi s-
ton i s at TDC.
Step 2: Move crankshaft rearward to l i mi ts of
travel .
Step 3: Then, move crankshaft forward to l i m-
i ts of travel .
Step 4: Wedge an approprai te tool between the
rear of the cyl i nder bl ock (NOT BED PLATE) and
the rear crankshaft counterwei ght. Thi s wi l l hol d the
crankshaft i n i ts furthest forward posi ti on.
Step 5: I nstal l and ti ghten bol ts (1-10) i n
sequence shown i n (Fi g. 84) to 41 Nm (30 ft. l bs.).
Step 6: Remove wedge tool used to hol d crank-
shaft.
(9) Ti ghten bol ts (1-10) agai n to 41 Nm (30 ft. l bs)
+ 1/4 turn i n sequence shown i n (Fi g. 84).
bol ts (11-20), and torque each bol t to 28 Nm (20 ft.
l bs.) i n sequence shown i n (Fi g. 84).
OIL FILTER
CAUTION: When servicing the oil filter avoid
deforming the filter can by installing the remove/in-
stall tool band strap against the can to base lock
seam. The lock seam joining the can to the base is
reinforced by the base plate.
(1) Turn countercl ockwi se to remove.
(2) To i nstal l , l ubri cate new fi l ter gasket. Check
fi l ter mounti ng surface. The surface must be smooth,
fl at and free of debri s or ol d pi eces of rubber. Screw
fi l ter on unti l the gasket contacts base. Ti ghten to 21
Nm (15 ft. l bs.).
OIL PUMP
REMOVAL
(2) Remove Ti mi ng Bel t. Refer to procedure out-
(3) Remove Oi l Pan. Refer to procedure outl i ned i n
thi s secti on.
(4) Remove Crankshaft Sprocket usi ng Speci al Tool
6793 and i nsert C-4685-C2 (Fi g. 85).
(5) Remove oi l pi ck-up tube.
(6) Remove oi l pump, (Fi g. 86) and front crank-
shaft seal .
INSTALLATION
(1) Make sure al l surfaces are cl ean and free of oi l
and di rt.
(2) Appl y Mopar Gasket Maker to oi l pump as
shown i n (Fi g. 87). I nstal l oi l ri ng i nto oi l pump body
di scharge passage.
(3) Pri me oi l pump before i nstal l ati on.
(4) Al i gn oi l pump rotor fl ats wi th fl ats on crank-
shaft as you i nstal l the oi l pump to the bl ock.
NOTE: Front crankshaft seal MUST be out of pump
to align, or damage may result.
(5) I nstal l new front crankshaft seal usi ng Speci al
Tool 6780 (Fi g. 88).
(6) I nstal l crankshaft sprocket, usi ng Speci al Tool
6792 (Fi g. 89).
(7) I nstal l oi l pump pi ck-up tube.
CAUTION: Installation and torque procedure for the
collar must be followed or damage could occur to
oil pan or collar.
(8) I nstal l oi l pan and col l ar. Refer to procedure
i n thi s secti on.
Fig. 86 Oil Pump and Pick-up Tube
Fig. 87 Oil Pump Sealing
PISTON AND CONNECTING ROD
REMOVAL
NOTE: Cylinder Head must be removed before Pis-
tons and Rods. Refer to Cylinder Head Removal in
this section.
(1) Remove top ri dge of cyl i nder bores wi th a rel i -
abl e ri dge reamer before removi ng pi stons from cyl -
i nder bl ock. Be sure to keep tops of pistons
covered during this operation. Mark pi ston wi th
matchi ng cyl i nder number (Fi g. 90).
(2) Remove oi l pan. Scri be the cyl i nder number on
the si de of the rod and cap (Fi g. 91) for i denti fi cati on.
(3) Pi stons have a di recti onal stampi ng i n the
front hal f of the pi ston faci ng towards the front of
engi ne.
(4) Pi stons and connecti ng rods must be removed
from top of cyl i nder bl ock. Rotate crankshaft so that
each connecti ng rod i s centered i n cyl i nder bore.
(5) Remove Bal ance Shaft Assembl y. Refer to Bal -
ance Shaft Removal i n thi s secti on.
(6) Remove connecti ng rod cap bol ts. Push each
pi ston and rod assembl y out of cyl i nder bore.
NOTE: Be careful not to nick crankshaft journals.
(7) After removal , i nstal l beari ng cap on the mat-
i ng rod.
(8) Pi ston and Rods are servi ced as an assembl y.
INSTALLATION
(1) Before i nstal l i ng pi stons and connecti ng rod
assembl i es i nto the bore, be sure that compressi on
ri ng gaps are staggered so that nei ther i s i n l i ne wi th
oi l ri ng rai l gap.
Fig. 88 Front Crankshaft SealInstallation
Fig. 90 Piston Markings
Fig. 91 Identify Connecting Rod to Cylinder
(2) Before i nstal l i ng the ri ng compressor, make
sure the oi l ri ng expander ends are butted and the
rai l gaps l ocated as shown i n (Fi g. 92). As vi ewed
from top.
(3) I mmerse the pi ston head and ri ngs i n cl ean
engi ne oi l , sl i de the ri ng compressor, over the pi ston
(Fi g. 93). Be sure position of rings does not
change during this operation.
(4) The di recti onal stamp on the pi ston shoul d
face toward the front of the engi ne (Fi g. 90).
(5) Rotate crankshaft so that the connecti ng rod
journal i s on the center of the cyl i nder bore. I nsert
rod and pi ston assembl y i nto cyl i nder bore and gui de
rod over the crankshaft journal .
(6) Tap the pi ston down i n cyl i nder bore, usi ng a
hammer handl e. At the same ti me, gui de connecti ng
rod i nto posi ti on on connecti ng rod journal .
NOTE: The rod bearing bolts should not be reused.
(7) Before i nstal l i ng the NEW bol ts the threads
shoul d be coated wi th cl ean engi ne oi l .
(8) I nstal l each bol t fi nger ti ght than al ternatel y
torque each bol t to assembl e the cap properl y.
CAUTION: Do not use a torque wrench for second
part of last step.
(9) Ti ghten the bol ts to 27 Nm PLUS 1/4 turn (20
ft. l bs. PLUS 1/4 turn).
(10) Usi ng a feel er gauge, check connecti ng rod
si de cl earance (Fi g. 94).
OIL PUMP
DISASSEMBLY
(1) To remove the rel i ef val ve, proceed as fol l ows:
(a) Remove the threaded pl ug and gasket from
the oi l pump (Fi g. 95).
(b) Remove spri ng and rel i ef val ve.
(2) Remove oi l pump cover screws, and l i ft off
cover.
(3) Remove pump rotors.
Fig. 93 PistonInstallation
Fig. 94 Checking Connecting Rod Side Clearance
Fig. 95 Oil Pressure Relief Valve
(4) Wash al l parts i n a sui tabl e sol vent and
i nspect careful l y for damage or wear.
ASSEMBLY
(1) Assembl e pump, usi ng new parts as requi red.
Install the inner rotor with chamfer facing the
cast iron oil pump cover.
(2) Pri me oi l pump before i nstal l ati on by fi l l i ng
rotor cavi ty wi th engi ne oi l .
(3) I nstal l cover and ti ghten screws to 12 Nm
(105 i n. l bs.).
CAUTION: Oil pump pressure relief valve must be
installed as shown in (Fig. 95) or serious damage
may occur.
(4) I nstal l rel i ef val ve, spri ng, gasket and cap as
shown i n (Fi g. 95). Ti ghten cap to 41 Nm (30 ft. l bs.)
CYLINDER HEAD
CLEANING
Remove al l gasket materi al from cyl i nder head and
bl ock. Be careful not to gouge or scratch the al umi -
num head seal i ng surface.
INSPECTION
(1) Cyl i nder head must be fl at wi thi n 0.1 mm
(0.004 i nch) (Fi g. 96).
(2) I nspect camshaft beari ng journal s for scori ng.
VALVE GUIDES
Chart. Repl ace gui des i f they are not wi thi n speci fi -
cati on.
VALVE AND VALVE SPRING
VALVES
Fig. 96 Checking Cylinder Head Flatness
Valve Guide Diameter
Intake and
Exhaust Valve:
5.975 - 6.000 mm
(0.2352 - 0.2362 in.)
New Service
Limit
Intake Valve: 0.048 - 0.066 mm
(0.0018 - 0.0025 in.)
0.25 mm
(0.010 in.)
Exhaust Valve: 0.0736 - 0.094 mm
(0.0029 - 0.0037 in.)
(.002 i n.), repl ace val ve.
VALVE SPRINGS
(1) Whenever val ves have been removed for
i nspecti on, recondi ti oni ng or repl acement, val ve
spri ngs shoul d be tested for correct tensi on. Di scard
the spri ngs that do not meet speci fi cati ons. The fol -
l owi ng speci fi cati ons appl y to both i ntake and
exhaust val ves spri ngs:
Val ve Cl osed Nomi nal Tensi on 76 l bs. @ 38.0
mm (1.50 i n.)
Val ve Open Nomi nal Tensi on 136 l bs. @ 29.75
mm (1.17 i n.)
(2) I nspect each val ve spri ng for squareness wi th
a steel square and surface pl ate, test spri ngs from
both ends. I f the spri ng i s more than 1.5 mm (1/16
i nch) out of square, i nstal l a new spri ng.
CRANKSHAFT
The crankshaft journal s shoul d be checked for
excessi ve wear, taper and scori ng (Fi g. 99). Li mi ts of
taper or out-of-round on any crankshaft journal s
shoul d be hel d to .025 mm (.001 i nch). Journal gri nd-
i ng shoul d not exceed .305 mm (.012 i nch) under the
standard journal di ameter. DO NOT gri nd thrust
faces of Number 3 mai n beari ng. DO NOT ni ck
crank pi n or beari ng fi l l ets. After gri ndi ng, remove
rough edges from crankshaft oi l hol es and cl ean out
al l passages.
CAUTION: With the nodular cast iron crankshafts
used it is important that the final paper or cloth pol-
ish after any journal regrind be in the same direc-
tion as normal rotation in the engine.
OIL PUMP
(1) Cl ean al l parts thoroughl y. Mati ng surface of
the oi l pump shoul d be smooth (Fi g. 100). Repl ace
pump cover i f scratched or grooved.
(2) Lay a strai ghtedge across the pump cover sur-
face (Fi g. 101). I f a 0.025 mm (0.001 i n.) feel er gauge
can be i nserted between cover and strai ght edge,
cover shoul d be repl aced.
(3) Measure thi ckness and di ameter of outer rotor.
I f outer rotor thi ckness measures 9.40 mm (0.370 i n.)
or l ess (Fi g. 102), or i f the di ameter i s 79.95 mm
(3.148 i n.) or l ess, repl ace outer rotor.
(4) I f i nner rotor measures 9.40 mm (0.370 i n.) or
l ess repl ace i nner rotor (Fi g. 103).
(5) Sl i de outer rotor i nto pump housi ng, press to
one si de wi th fi ngers and measure cl earance between
rotor and housi ng (Fi g. 104). I f measurement i s 0.39
mm (0.015 i n.) or more, repl ace housi ng onl y i f outer
rotor i s i n speci fi cati on.
(6) I nstal l i nner rotor i nto pump housi ng. I f cl ear-
ance between i nner and outer rotors (Fi g. 105) i s
0.203 mm (0.008 i n.) or more, repl ace both rotors.
(7) Pl ace a strai ghtedge across the face of the
pump housi ng, between bol t hol es. I f a feel er gauge
of 0.102 mm (0.004 i n.), or more can be i nserted
Fig. 99 Crankshaft Journal Measurements
Fig. 100 Oil Pump
Fig. 101 Checking Oil Pump Cover Flatness
between rotors and the strai ghtedge, repl ace pump
assembl y (Fi g. 106), ONLY i f rotors are i n specs.
(8) I nspect oi l pressure rel i ef val ve pl unger for
scori ng and free operati on i n i ts bore. Smal l marks
may be removed wi th 400 gri t wet or dry sandpaper.
(9) The rel i ef val ve spri ng has a free l ength of
approxi matel y 60.7 mm (2.39 i nches) i t shoul d test
between 18 and 19 pounds when compressed to 40.5
mm (1.60 i nches). Repl ace spri ng that fai l s to meet
speci fi cati ons.
(10) I f oi l pressure i s l ow and pump i s wi thi n
speci fi cati ons, i nspect for worn engi ne beari ngs or
other reasons for oi l pressure l oss.
Fig. 102 Measuring Outer Rotor Thickness
Fig. 103 Measuring Inner Rotor Thickness
Fig. 104 Measuring Outer Rotor Clearance in
Housing
Fig. 105 Measuring Clearance Between Rotors
Fig. 106 Measuring Clearance Over Rotors
CYLINDER BLOCK
(1) Cl ean cyl i nder bl ock thoroughl y and check al l
core hol e pl ugs for evi dence of l eaki ng.
(2) I f new core pl ugs are i nstal l ed, refer to Engi ne
Core Pl ugs outl i ned i n thi s secti on.
(3) Exami ne bl ock and cyl i nder bores for cracks or
fractures.
CYLINDER BORE INSPECTION
The cyl i nder wal l s shoul d be checked for out-of-
round and taper wi th Tool C119 (Fi g. 107). The cyl -
i nder bore out-of-round i s 0.050 mm (0.002 i n.)
maxi mum and cyl i nder bore taper i s 0.051 mm (0.002
i n.) maxi mum. I f the cyl i nder wal l s are badl y scuffed
or scored, the cyl i nder bl ock shoul d be repl aced, and
new pi stons and ri ngs fi tted.
Measure the cyl i nder bore at three l evel s i n di rec-
ti ons A and B (Fi g. 107). Top measurement shoul d be
10 mm (3/8 i n.) down and bottom measurement
shoul d be 10 mm (3/8 i n.) up from bottom of bore.
Refer to Cyl i nder Bore and Pi ston Speci fi cati on
Chart.
ADJ USTMENTS
ENGINE MOUNTS
ENGINE MOUNT INSULATOR ADJ USTMENT
(1) Remove the l oad on the engi ne motor mounts
by careful l y supporti ng the engi ne and transmi ssi on
assembl y wi th a fl oor jack.
(2) Loosen the ri ght engi ne mount i nsul ator verti -
cal fastener and the fore and aft fasteners, and the
front engi ne mount bracket to front crossmember
screws.
(3) Pry the engi ne ri ght or l eft as requi red to
achi eve the proper dri ve shaft assembl y l ength. Refer
to Group 2, Suspensi on and Dri veshafts for dri ve-
shaft i denti fi cati on and rel ated assembl y l ength mea-
suri ng.
(4) Ti ghten engi ne mounts and fasteners i n the
fol l owi ng order:
(a) Ri ght engi ne mount i nsul ator verti cal bol ts
to 102 Nm (75 ft. l bs.) and the fore and aft bol ts to
150 Nm (110 ft. l bs.).
(b) Front engi ne mount screws to 54 Nm (40 ft.
l bs.) the cl earance between the snubbers and the
engi ne shoul d be 2 mm (0.078 i nch.) each si de.
(c) Left engi ne mount through bol t to 75 Nm (55
ft. l bs.).
(5) Recheck dri veshaft l ength.
SPECIFICATION CHART
Standard Bore Maximum Out-
Of-Round
Maximum-
Taper
87.5 mm 0.051 mm 0.051 mm
(3.445 in.) (0.002 in.) (0.002 in.)
87.450 - 87.468 mm (3.4434 - 3.4441 in.)
Piston To Bore Clearance
0.024 - 0.057 mm (0.0009 - 0.0022 in.)
Measurements taken at Piston Size Location.
SPECIFICATIONS
2. 4L ENGINE
Type . . . . . . . . . . . . . . . . . . . .I n-Li ne OHV, DOHC
Number of Cyl i nder . . . . . . . . . . . . . . . . . . . . . . .4
Bore . . . . . . . . . . . . . . . . . . . . .87.5 mm (3.445 i n.)
Stroke . . . . . . . . . . . . . . . . . . . .101 mm (3.976 i n.)
Compressi on Rati o. . . . . . . . . . . . . . . . . . . . . .9.4:1
Di spl acement . . . . . . .2.4 Li ters (148 Cubi c I nches)
Fi ri ng Order . . . . . . . . . . . . . . . . . . . . . . .1, 3, 4, 2
Compressi on Pressure . . . . . . . . . . .1172-1551 kPa
(170-225 psi )
Maxi mum Vari ati on Between Cyl i nder . . . . . .25 %
Lubri cati on . . . .Pressure Feed-Ful l Fl ow Fi l trati on
(Di rect Crankshaft Dri ven Pump)
Cylinder Block
Cyl i nder Bore Di ameter . . . .87.4924 - 87.5076 mm
(3.4446 - 3.4452 i n.)
Out-of-Round (Max.). . . . . . . .0.051 mm (0.002 i n.)
Taper (Max.). . . . . . . . . . . . . .0.051 mm (0.002 i n.)
Pistons
Cl earance at 14 mm (9/16 i n.)
From Bottom of Ski rt . . . . . . . . .0.024 - 0.057 mm
(0.0009 - 0.0022 i n.)
Wei ght . . . . . . . . . . . . . . . . . . . . . .332 - 346 grams
(11.85 - 12.20 oz.)
Top Land Cl earance
(Di ametri cal ). . . . . . . . . . . . . . . .0.614 - 0.664 mm
(0.024 - 0.026 i n.)
Pi ston Length . . . . . . . . . . . . .60.30 mm (2.374 i n.)
Piston Ring Groove Depth
No. 1 . . . . . . . .4.640 - 4.784 mm (0.182 - 0.188 i n.)
No. 2 . . . . . . . .4.575 - 4.719 mm (0.180 - 0.185 i n.)
No. 3 . . . . . . . .4.097 - 4.236 mm (0.161 - 0.166 i n.)
Piston Pins
Cl earance i n Pi ston . . . . . . . . . . .0.005 - 0.018 mm
I n Rod (I nterference) . . . . . . . . . .0.018 - 0.043 mm
(0.0007 - 0.0017 i n.)
Di ameter . . . . . . . . . . . . . . . . .21.998 - 22.003 mm
(0.8660 - 0.8662 i n.)
End Pl ay . . . . . . . . . . . . . . . . . . . . . . . . . . . . .None
Length . . . . . . . . . . . . . . . . . . . . .72.75 - 73.25 mm
(2.864 - 2.883 i n.)
Piston Ring Gap
Top Compressi on Ri ng . . . . . . . . . . .0.25 - 0.51 mm
(0.0098 - 0.020 i n.)
2nd Compressi on Ri ng. . . . . . . . . . .0.23 - 0.48 mm
(0.009 - 0.018 i n.)
Oi l Control (Steel Rai l s) . . . . . . . . .0.25 - 0.64 mm
(0.0098 - 0.025 i n.)
Piston Ring Side Clearance
Top and Second
Compressi on Ri ngs . . . . . . . . . . .0.030 - 0.080 mm
(0.0011 - 0.0031 i n.)
Oi l Ri ng (Pack) . . . . . . . . . . . . . .0.012 - 0.178 mm
(0.0004 - 0.0070 i n.)
Piston Ring Width
Compressi on Ri ngs . . . . . . . . . . . . .1.47 - 1.50 mm
(0.057 - 0.059 i n.)
Oi l Ri ng (Pack) . . . . . . . . . . . . . . . .2.72 - 2.88 mm
(0.107 - 0.1133 i n.)
Connecting Rod
Beari ng Cl earance . . . . . . . . . . . .0.025 - 0.071 mm
(0.0009 - 0.0027 i n.)
Pi ston Pi n Bore Di ameter . . . . . .20.96 - 20.98 mm
(0.8252 - 0.8260 i n.)
Large End Bore Di ameter . . . .53.007 - 52.993 mm
(2.0868 - 2.0863)
Si de Cl earance . . . . . . . . . . . . . .0.013 - 0.0150 mm
(0.0051 - 0.0150 i n.)
Total Wei ght (Less Beari ng). . . . . . . . .565.8 grams
(19.96 oz.)
Crankshaft
Connecti ng Rod
Journal Di ameter . . . . . . . . . .49.984 - 50.000 mm
(1.967 - 1.9685 i n.)
Out-of-Round (Max.) . . . . . .0.0035 mm (0.0001 i n.)
Taper (Max.) . . . . . . . . . . . .0.0038 mm (0.0001 i n.)
Mai n Beari ng Di ametri cal
Cl earance No. 1 - 5 . . . . . . . . . . .0.018 - 0.058 mm
(0.0007 - 0.0023 i n.)
End Pl ay . . . . . . . . . . . . . . . . . . . . .0.09 - 0.24 mm
(0.0035 - 0.0094 i n.)
Main Bearing J ournals
Di ameter . . . . . . . . . . . . . . . . .59.992 - 60.008 mm
(2.361 - 2.3625 i n.)
Out-of-Round (Max.) . . . . . .0.0035 mm (0.0001 i n.)
Taper (Max.) . . . . . . . . . . . . . . .0.0038 (0.0001 i n.)
Hydraulic Lash Adjusters
Body Di ameter . . . . . . . . . . . . .15.901 - 15.913 mm
(0.626 - 0.6264 i n.)
Pl unger Travel Mi ni mum (Dry). . . . . . . . . .3.0 mm
(0.118 i n.)
Camshaft
Beari ng Bore
Di ameters No. 16. . . . . . . . . .26.020 - 26.041 mm
(1.024 - 1.025 i n.)
Di ametri cal Beari ng Cl earance . .0.069 - 0.071 mm
(0.0027 - 0.003 i n.)
End Pl ay . . . . . . . . . . . . . . . . . . .0.050 - 0.170 mm
(0.0019 - 0.0066 i n.)
Beari ng Journal
Di ameter No. 16 . . . . . . . . . .25.951 - 25.970 mm
(1.021 - 1.022 i n.)
Li ft (Zero Lash) I ntake . . . . . . .8.25 mm (0.324 i n.)
Li ft (Zero Lash) Exhaust . . . . .6.52 mm (0.256 i n.)
Valve Timing Intake Valve
Cl oses (ABDC) . . . . . . . . . . . . . . . . . . . . . . . . . .51
Opens (BTDC) . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Durati on . . . . . . . . . . . . . . . . . . . . . . . . . . . . .232
Valve Timing Exhaust Valve
Cl oses (ATDC) . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Opens (BBDC) . . . . . . . . . . . . . . . . . . . . . . . . . .52
Durati on . . . . . . . . . . . . . . . . . . . . . . . . . . . . .240
Valve Timing
Val ve Overl ap . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Cylinder Head
Materi al . . . . . . . . . . . . . . . . . . . . .Cast Al umi num
Gasket Thi ckness (Compressed) . . . . . . . .1.15 mm
(0.045 i n.)
Cylinder Head Valve Seat
Angl e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Runout (Max.). . . . . . . . . . . . .0.050 mm (0.002 i n.)
Wi dth (Fi ni sh) I ntake and Exhaust. . .0.9 - 1.3 mm
(0.035 - 0.051 i n.)
Gui de Bore Di ameter (Std). . . . . . .11.0 - 11.02 mm
(0.4330 - 0.4338 i n.)
Fi ni sh Gui de Bore I D. . . . . . . . . .5.975 - 6.000 mm
(0.235 - 0.236 i n.)
Valves
Face Angl e . . . . . . . . . . . . . . . . . . . . . .44-1/2 - 45
Head Di ameter I ntake . . . . . . . . .34.67 - 34.93 mm
(1.364 - 1.375 i n.)
Head Di ameter Exhaust . . . . . . .30.37 - 30.63 mm
(1.195 - 1.205 i n.)
LengthI ntake (Overal l ). . . . . .112.76 - 113.32 mm
(4.439 - 4.461 i n.)
LengthExhaust (Overal l ) . . . .109.59 - 110.09 mm
(4.314 - 4.334 i n.)
Val ve Margi nI ntake . . . . . . . . . .1.285 - 1.615 mm
(0.050 - 0.063 i n.)
Val ve Margi nExhaust . . . . . . . .0.985 - 1.315 mm
(0.038 - 0.051 i n.)
Val ve Stem Ti p Hei ghtI ntake . . . . . . . .48.04 mm
(1.891 i n.)
Valves
Val ve Stem Ti p Hei ghtExhaust . . . . . . .47.99 mm
(1.889 i n.)
Stem Di ameterI ntake . . . . . . . .5.934 - 5.952 mm
(0.234 - 0.234 i n.)
Stem Di ameterExhaust . . . . . . .5.906 - 5.924 mm
(0.233 - 0.233 i n.)
Stem-to-Gui de
Cl earanceI ntake . . . . . . . . . . . .0.048 - 0.066 mm
(0.0018 - 0.0025 i n.)
Stem-to-Gui de
Cl earanceExhaust . . . . . . . . . .0.0736 - 0.094 mm
(0.0029 - 0.0037 i n.)
Max. Al l owabl e Stem-to-Gui de
Cl earanceI ntake and Exhaust . . . . . . .0.025 mm
(0.010 i n.)
Valve Springs
Free Length (Approx.) . . . . . . .48.4 mm (1.905 i n.)
Spri ng Tensi on
(Val ve Cl osed) . . . . . . . . .338 N 20 N @ 38.0 mm
(75.98 l bs. 4.5 l bs. @ 1.496 i n.)
Spri ng Tensi on
(Val ve Open) . . . . . . . . .607 N 30 N @ 29.75 mm
(136 l bs. 7 @ 1.172 i n.)
Number of Coi l s . . . . . . . . . . . . . . . . . . . . . . . .7.82
Wi re Di ameter . . . . . . . . . . . . .3.86 mm (0.151 i n.)
I nstal l ed Spri ng Hei ght . . . . .38.00 mm (1.496 i n.)
Oil Pump
Cl earance Over Rotors (Max.). .0.10 mm (0.004 i n.)
Cover Out-of-Fl at (Max.). . . . .0.025 mm (0.001 i n.)
I nner Rotor Thi ckness (Mi n.) . .9.40 mm (0.370 i n.)
Outer Rotor (Oil Pump)
Cl earance (Max.) . . . . . . . . . . .0.39 mm (0.015 i n.)
Di ameter (Mi n.) . . . . . . . . . . .79.95 mm (3.148 i n.)
Thi ckness (Mi n.). . . . . . . . . . . .9.40 mm (0.370 i n.)
Ti p Cl earance Between Rotors (Max.) . . . .0.20 mm
(0.008 i n.)
Oil Pressure
At Curb I dl e Speed* . . . . . . . . . . . . .25 kPa (4 psi )
At 3000 rpm . . . . . . . . .170 - 550 kPa (25 - 80 psi )
CAUTION: * If pressure is ZERO at curb Idle, DO
NOT run engine at 3,000 rpm.
TORQUE CHART 2. 4L
DESCRIPTION TORQUE
Balance Shaft Carrier to Block
Bol ts . . . . . . . . . . . . . . . . . . . . .54 Nm (40 ft. l bs.)
Balance Shaft Gear Cover
Doubl e Ended Fastener . . . . . .12 Nm (105 i n. l bs.)
Balance Shaft Sprockets
Bol ts . . . . . . . . . . . . . . . . . . . .28 Nm (250 i n. l bs.)
Balance Shaft Chain Tensioner
Bol ts . . . . . . . . . . . . . . . . . . . .12 Nm (105 i n. l bs.)
Balance Shaft Carrier Cover
Fasteners . . . . . . . . . . . . . . . .12 Nm (105 i n. l bs.)
Camshaft Sensor Pick Up
Bol ts . . . . . . . . . . . . . . . . . . . . .27 Nm (20 ft. l bs.)
Timing Belt Cover
Outer to I nner Attachi ng Bol ts M6. . . . . . .4.5 Nm
(40 i n. l bs.)
I nner Cover to Head/Oi l Pump Bol ts M6. . .12 Nm
(105 i n. l bs.)
Camshaft Sprocket
Bol t . . . . . . . . . . . . . . . . . . . . .101 Nm (75 ft. l bs.)
Connecting Rod Cap
Bol ts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27 Nm
(20 ft. l bs.) Pl us 1/4 Turn
Crankshaft Main Bearing Cap/Bedplate
M8 Bedpl ate Bol ts . . . . . . . . .34 Nm (250 i n. l bs.)
Mai n Cap Bol ts M11 . . . . . . . . . . . . . . . . . .41 Nm
Crankshaft Damper
Bol t . . . . . . . . . . . . . . . . . . . .135 Nm (100 ft. l bs.)
Cylinder Head
Bol ts . . . . . . . .Refer To Cyl i nder Head I nstal l ati on
Cylinder Head Cover
Bol ts . . . . . . . . . . . . . . . . . . . .12 Nm (105 i n. l bs.)
DESCRIPTION TORQUE
Engine Mount Bracket
Bol ts . . . . . . . . . . . . . . . . . . . . .61 Nm (45 ft. l bs.)
Engine MountFront and Rear
Through Bol t . . . . . . . . . . . . . . .61 Nm (45 ft. l bs.)
Exhaust Manifold to Cylinder Head
Bol ts . . . . . . . . . . . . . . . . . . . .23 Nm (200 i n. l bs.)
Exhaust Manifold Heat Shield
Bol ts . . . . . . . . . . . . . . . . . . . .12 Nm (105 i n. l bs.)
Front Torque Bracket2.0/2.4L Engine
Bol ts . . . . . . . . . . . . . . . . . . . . .33 Nm (24 ft. l bs.)
Front Torque Bracket Strut2.0/2.4L Engine
Long Bol ts . . . . . . . . . . . . . . . .110 Nm (80 ft. l bs.)
Short Bol t . . . . . . . . . . . . . . . . .61 Nm (45 ft. l bs.)
Intake Manifold
Bol ts . . . . . . . . . . . . . . . . . . . . .27 Nm (20 ft. l bs.)
Oil Filter
Fi l ter . . . . . . . . . . . . . . . . . . . . .20 Nm (15 ft. l bs.)
Oil Pan
Oi l Pan Bol ts . . . . . . . . . . . . .12 Nm (105 i n. l bs.)
Drai n Pl ug. . . . . . . . . . . . . . . . .27 Nm (20 ft. l bs.)
Oil Pump Attaching
Bol ts . . . . . . . . . . . . . . . . . . . .28 Nm (250 i n. l bs.)
Oi l Pump Cover Fastener . . . .12 Nm (105 i n. l bs.)
Oi l Pump Pi ck-up Tube Bol t . .28 Nm (250 i n. l bs.)
Oi l Pump Rel i ef Val ve Cap . . . .41 Nm (30 ft. l bs.)
Rear Torque Bracket
Bol ts . . . . . . . . . . . . . . . . . . . .110 Nm (80 ft. l bs.)
Spark Plugs
Pl ugs . . . . . . . . . . . . . . . . . . . . .28 Nm (20 ft. l bs.)
Thermostat Housing
Bol ts . . . . . . . . . . . . . . . . . . . .23 Nm (200 i n l bs.)
Timing Belt Tensioner Assembly
Bol ts . . . . . . . . . . . . . . . . . . . . .61 Nm (45 ft. l bs.)
Water Pump Mounting
Bol ts . . . . . . . . . . . . . . . . . . . .12 Nm (105 i n. l bs.)
SPECIAL TOOLS
2. 4L ENGINE
Puller 1026
Crankshaft Damper Removal Insert 6827-A
Dolly 6135
Cradle 6710
Post Kit Engine Cradle 6848
Camshaft Sprocket Remover/Installer C-4687
Camshaft Sprocket Remover/Installer Adapter
C-4687-1
Camshaft Seal Remover C-4679-A
Camshaft Seal Installer MD-998306
Crankshaft Damper Installer 6792
Valve Spring Compressor MD-998772-A
Valve Spring Compressor Adapter 6779
Cylinder Bore Gage C-119
Crankshaft Sprocket Remover 6793
Crankshaft Sprocket Remover Insert C-4685-C2
SPECIAL TOOLS (Continued)
Crankshaft Seal Remover 6771
Oil Pressure Gage C-3292
Rear Crankshaft Seal Guide and Installer 6926-1 and
6926-2
Balance Shaft Sprocket Installer 6052
Post Kit Engine Cradle 6848
Post Adapter 8130
Front Crankshaft Oil Seal Installer 6780
3.0L ENGINE
INDEX
page page
ENGINE IDENTIFICATION NUMBER . . . . . . . . . 61
ENGINE LUBRICATION . . . . . . . . . . . . . . . . . . . 61
SERVICE PROCEDURES
AUTO LASH ADJUSTER . . . . . . . . . . . . . . . . . . . 62
CHECKING CRANKSHAFT END PLAY . . . . . . . . 65
FITTING CONNECTING ROD BEARINGS . . . . . . 63
FITTING MAIN BEARING . . . . . . . . . . . . . . . . . . 63
VALVE SERVICE RECONDITION . . . . . . . . . . . . 66
CAMSHAFT SEAL . . . . . . . . . . . . . . . . . . . . . . . 72
CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . 81
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . 73
ENGINE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 69
ENGINE MOUNTS . . . . . . . . . . . . . . . . . . . . . . . 68
FRONT CRANKSHAFT OIL SEAL . . . . . . . . . . . . 83
OIL FILTER AND ADAPTOR . . . . . . . . . . . . . . . . 84
OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
PISTON AND CONNECTING ROD . . . . . . . . . . . 78
REAR CRANKSHAFT SEAL . . . . . . . . . . . . . . . . 83
ROCKER ARMS . . . . . . . . . . . . . . . . . . . . . . . . . 72
TIMING BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
ROCKER ARMS AND SHAFTS . . . . . . . . . . . . . . 85
CYLINDER BORE . . . . . . . . . . . . . . . . . . . . . . . . 87
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . 86
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
TIMING BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
ADJUSTMENTS
ENGINE MOUNTS . . . . . . . . . . . . . . . . . . . . . . . 88
SPECIFICATIONS
3.0L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
TORQUE CHART 3.0L . . . . . . . . . . . . . . . . . . . . 90
SPECIAL TOOLS
3.0L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
ENGINE IDENTIFICATION NUMBER
rear of the cyl i nder bl ock just bel ow the cyl i nder
head (Fi g. 1).
ENGINE LUBRICATION
System i s a ful l fl ow fi l trati on, pressure feed type.
The oi l pump i s mounted behi nd the ti mi ng bel t
cover. The pump i nner rotor i s dri ven by the crank-
shaft. The engi ne oi l pan contai ns a baffl e pl ate to
control oi l l evel fl uctuati on duri ng engi ne operati on.
ENGINE COMPONENTS
BLOCK: The cyl i nder bl ock i s a l i ght wei ght
desi gn created by reduci ng thi ckness i n many parts
and a short 10 mm (3/8 i n.) bl ock ski rt. Hi gh ri gi di ty
i s provi ded wi th ri bs cast i n the outer wal l , a ful l
l ength water jacket, and a mono-bl ock or beam type,
mai n beari ng cap. Thi s si ngl e uni t four beari ng cap
i s desi gned to control vi brati on of the cyl i nder bl ock
parti ti on wal l s.
CRANKSHAFT: A si x throw, fi ve wei ght crank-
shaft i s supported by four mai n beari ngs wi th num-
ber three bei ng the thrust beari ng. The si x separate
connecti ng rod throws pi ns reduce torque fl uctua-
ti ons whi l e a torsi onal vi brati on damper i s used to
control torsi on caused vi brati on of the crankshaft.
Rubber l i pped seal s are used at front and rear. The
front seal i s retai ned i n the oi l pump case and the
rear i s retai ned i n a bl ock-mounted housi ng.
PISTONS: Are al umi num al l oy wi th a steel strut,
short hei ght, and thi n wal l so as to be autothermi c
and l i ght wei ght. The pi ston head wi th val ve
recesses, i n combi nati on wi th the cyl i nder head,
forms a compact spheri cal head wi th cl earance for
total val ve l i ft wi th pi stons at top dead center. The
pi ston ski rt, top and second ri ng l ands are fi ni shed to
a tapered roughness for oi l retenti on and hi gh resi s-
tance to scuffi ng. Pi ston pi ns, pressed i nto pl ace, joi n
the pi stons to the connecti ng rods.
CYLINDER HEAD: The al l oy cyl i nder heads fea-
ture cross-fl ow type i ntake and exhaust ports. Val ve
gui des and i nserts are hardened cast i ron. Val ves of
heat resi stance steel are arranged i n a V wi th each
camshaft on center. To i mprove combusti on speed the
chambers are a compact spheri cal desi gn wi th a
squi sh area of approxi matel y 30 percent of the pi ston
top area. The cyl i nder heads are common to ei ther
cyl i nder bank by reversi ng the di recti on of i nstal l a-
ti on.
CAMSHAFTS: Two overhead camshafts provi de
val ve actuati on, one front (radi ator si de of cyl i nder
bank) and one rear. The front camshaft i s provi ded
wi th a di stri butor dri ve and i s l onger. Both cam-
shafts are supported by four beari ng journal s, thrust
for the front camshaft i s taken at journal two and
the rear at journal three. Front and rear camshaft
dri vi ng sprockets are i nterchangeabl e. The sprockets
and the engi ne water pump are dri ven by a si ngl e
notched ti mi ng bel t.
ROCKER ARM SHAFTS: The shafts are retai ned
by the camshaft beari ng journal caps. Four shafts are
used, one for each i ntake and exhaust rocker arm
assembl y on each cyl i nder head. The hol l ow shafts
provi de a duct for l ubri cati ng oi l fl ow from the cyl i n-
der head to the val ve mechani sms.
ROCKER ARMS: Are of l i ght wei ght di e-cast wi th
rol l er type fol l ower operati ng agai nst the cam shaft.
The val ve actuati ng end of the rocker arms are
machi ned to retai n hydraul i c l ash adjusters, el i mi -
nati ng val ve l ash adjustment.
VALVES: Are made of heat resi stant steel , val ve
spri ngs are especi al l y desi gned to be short. The val ve
spri ng wi re cross-secti on i s oval shaped and provi des
the same spri ng tensi on as l onger spri ngs. Val ve
spri ng retai ners, l ocks and seal s are conventi onal .
INTAKE MANIFOLD: The al umi num al l oy mani -
fol d i s a cross type wi th l ong runners to i mprove
i nerti a. The runners, attachi ng bel ow at the cyl i nder
head, al so attach above and support an ai r pl enum.
The ai r pl enum chamber absorbs ai r pul sati ons cre-
ated duri ng the sucti on phase of each cyl i nder.
EXHAUST MANIFOLDS: Both mani fol ds are a
l og styl e made of ducti l e cast i ron. Exhaust gasses,
col l ected from the front cyl i nder bank, l eave the front
mani fol d through an end outl et and are fed through
an upper crossover tube to the rear mani fol d. The
col l ected exhaust from both mani fol ds are combi ned,
and exi t to the exhaust pi pe through an arti cul ated
joi nt.
Check oi l pressure usi ng gauge at oi l pressure
swi tch l ocati on. Oi l pressure shoul d be 41 kPa ( 6
psi .) at i dl e or 241 to 517 kPa (35 to 75 psi .) at 3000
RPM.
(1) Remove pressure sendi ng uni t and i nstal l oi l
pressure gauge. (Fi g. 2).
CAUTION: If oil pressure is 0 at idle, Do Not Run
engine at 3000 RPM.
(2) Warm engi ne at hi gh i dl e unti l thermostat
opens.
SERVICE PROCEDURES
AUTO LASH ADJUSTER
The automati c l ash adjusters are preci si on uni ts
i nstal l ed i n machi ned openi ngs i n the val ve actuati ng
ends of the rocker arms. Do not di sassembl e the auto
l ash adjuster.
FUNCTION CHECK
Check auto adjusters for free pl ay by i nserti ng a
smal l wi re through the ai r bl eed hol e i n the rocker
arm and very lightly pushi ng the auto adjuster bal l
check down (Fi g. 3). Whi l e l i ghtl y hol di ng the check
bal l down move the rocker up and down to check for
free pl ay. I f there i s no pl ay repl ace the adjuster.
Fig. 2 Checking Engine Oil Pressure
CONNECTING ROD CLEARANCE
(1) Fol l owi ng procedures speci fi ed i n the Standard
Servi ce Procedures Secti on for Measuri ng Mai n Bear-
i ng Cl earance and Connecti ng Rod Beari ng Cl ear-
ance (Fi g. 4). Refer to Connecti ng Rod Speci fi cati on
Chart.
(2) Ti ghten nuts to 52 Nm (38 ft. l bs.).
(3) Remove connecti ng rod cap and measure Pl as-
ti gage (Fi g. 4).
CAUTION: Do not rotate crankshaft or the Plasti-
gage may be smeared.
CONNECTING ROD SIDE CLEARANCE
Usi ng a feel er gauge, check connecti ng rod si de
cl earance (Fi g. 5). Refer to Connecti ng Rod Speci fi ca-
ti on Chart.
FITTING MAIN BEARING
INSPECTION
Vi sual l y check the mai n and connecti ng rod bear-
i ng journal s for wear, scuffs or scori ng and repl ace i f
necessary.
CRANKSHAFT OIL CLEARANCE
MECHANICAL MEASUREMENT
Measure the journal outsi de di ameter and the
mai n beari ng i nsi de di ameter (Fi g. 6) & (Fi g. 7). I f
the cl earance exceeds the speci fi cati ons l i mi t, repl ace
the mai n beari ng(s) and i f necessary repl ace the
crankshaft. Refer to Crankshaft Cl earance Speci fi ca-
ti on Chart.
PLASTIGAGE MEASUREMENT
(1) Remove oi l from journal and beari ng shel l .
(2) I nstal l crankshaft.
(3) Cut pl asti gage to same l ength as wi dth of the
beari ng and pl ace i t i n paral l el wi th the journal axi s
(Fi g. 8).
Fig. 3 Auto Lash AdjusterFunction Check
Fig. 4 Connecting RodChecking Bearing
Clearance
CONNECTING ROD SPECIFICATION CHART
Connecting Rod Bearing Oil Clearance
New Part: 0.018 - 0.036 mm
(0.0007 - 0.0014 in.)
Connecting Rod Side Clearance
New Part: 0.10 - 0.25 mm
(0.004 - 0.010 in.)
CAUTION: Do not rotate crankshaft or the plasti-
gage will be smeared.
(4) I nstal l the mai n beari ng cap careful l y and
ti ghten the bol ts to speci fi ed torque.
(5) Careful l y remove the beari ng cap and measure
the wi dth of the pl asti gage at the wi dest part usi ng
the scal e on the pl asti gage package (Fi g. 9). Refer to
Crankshaft Cl earance Speci fi cati on Chart for proper
cl earances. Al so see Measuri ng Mai n and Connecti ng
Rod Beari ng Cl earance i n Standard Servi ce Proce-
dures.
CRANKSHAFT BEARING INSTALLATION
When the beari ngs need repl aci ng, sel ect and
i nstal l the proper beari ng by the fol l owi ng procedure.
(1) Measure the crankshaft journal di ameter and
confi rm i ts cl assi fi cati on from the fol l owi ng. I n the
case of a beari ng suppl i ed as a servi ce part, i ts i den-
ti fi cati on col or i s pai nted at the posi ti on show i n (Fi g.
10).
NOTE: Service replacement parts have identifica-
tion marks, but factory-assembled parts have no
identification marks. Service crankshaft identifica-
tion may have marks or paint at counterweights.
Refer to Crankshaft Size Classification Chart.
Fig. 6 Measure Crankshaft Journal O.D.
Fig. 7 Measure Main Bearing I.D.
Crankshaft End-Play
New Part: 0.05 - 0.25 mm
(0.002 - 0.001 in.)
Main Bearing Oil Clearance
New Part: 0.018 - 0.036 mm
(0.0007 - 0.0014 in.)
Wear Part: 0.10 mm (0.0039 in.)
Crankshaft Main Bearing Journal
Standard Diameter: 59.980 mm (2.361 in.)
Crankshaft Connecting Rod Journal
Fig. 8 Measure Oil Clearance with Plastigage
Fig. 9 Measuring Clearance
CHECKING CRANKSHAFT END PLAY
travel .
cati on Chart.
CRANKSHAFT SIZE CLASSIFICATION CHART
SIZE NEW CURRENT
MAIN JOURNAL
59.982 - 59.988 mm
(2.3615 - 2.3617 in.)
2 WHITE
ENAMEL
59.988 - 59.994 mm
(2.3617 - 2.3620 in.)
1 NONE
59.994 - 60.000 mm
(2.3620 - 2.3622 in.)
0 YELLOW
ENAMEL
CONNECTING ROD JOURNAL
49.980 - 49.985 mm
(1.9677 - 1.9679 in.)
III WHITE
ENAMEL
49.985 - 49.995 mm
(1.9679 - 1.9683 in.)
II NONE
49.995 - 50.000 mm
(1.9683 - 1.9685 in.)
I YELLOW
ENAMEL
Fig. 10 Bearing Identification
Fig. 11 Checking Crankshaft End Play
Crankshaft End-Play
New Part: 0.05 - 0.25 mm
0.002 - 0.001 in.)
Main Bearing Oil Clearance
New Part: 0.018 - 0.036 mm
(0.0007 - 0.0014 in.)
Wear Part: 0.10 mm (0.0039 in.)
(1) Wi th sui tabl e val ve spri ng compressor, remove
spri ng retai ner l ocks, retai ner, val ve spri ng, spri ng
seat and val ve (Fi g. 12).
(2) Remove val ve stem seal s wi th sui tabl e tool
(Fi g. 13). Do not reuse val ve stem seal s.
VALVES
(1) Check val ve stem ti p for pi tti ng or depressi on
at poi nt A (Fi g. 14).
(2) Check for wear and ri dge wear at Poi nt B.
(3) Check for even contact (at face center) wi th
val ve seat, Poi nt C.
(4) Check margi n (Fi g. 14). Repl ace val ve i f mar-
gi n i s out of speci fi cati on. Refer to Val ve Speci fi cati on
Chart.
(6) Measure val ve stem to gui de cl earance. Refer
to Val ve Speci fi cati on Chart.
(7) Measure Val ve spri ng free l ength and square-
ness (Fi g. 16). Refer to Val ve Speci fi cati on Chart.
Fig. 12 Remove Valves
Fig. 13 Remove Valve Stem Seals
Fig. 14 Valve Inspection
VALVE SEAT
I nspect the val ve seat wi th Prussi an bl ue to deter-
mi ne where the val ve contacts the seat. To do thi s,
coat val ve seat LIGHTLY wi th Prussi an bl ue then
set val ve i n pl ace. Rotate the val ve wi th l i ght pres-
sure. I f the bl ue i s transferred to the center of val ve
face, contact i s sati sfactory. I f the bl ue i s transferred
to top edge of the val ve face, l ower val ve seat wi th a
15 degrees stone. I f the bl ue i s transferred to the bot-
tom edge of val ve face rai se val ve seat wi th a 65
degree stone (Fi g. 17).
INSTALLATION
(1) I nstal l val ve spri ng seat.
(2) Usi ng sui tabl e tool i nstal l seal by tappi ng
l i ghtl y unti l seal i s i n pl ace (Fi g. 18).
(3) I nstal l val ve spri ng wi th the enamel l ed ends
faci ng the rocker arms (Fi g. 19).
CAUTION: During reassembly, compressing the
valve spring more than necessary to install valve
spring retainer locks can cause the retainer to be
forced against the stem seal and damaging it.
Valve Dimensions
INTAKE VALVE (MINIMUM)
Stem Diameter: 7.960 mm (0.313 in.)
Face Angle: 45
Valve Margin: 0.700 mm (0.028 in.)
Length: 103.0 mm (4.055 in.)
EXHAUST VALVE (MINIMUM)
Stem Diameter: 7.930 mm (0.312)
Face Angle: 45
Length: 102.70 mm (4.043 in.)
Valve Guide
Clearance
New Service
Limit
Intake: 0.03 - 0.06 mm
(0.001 - 0.002 in.)
0.10 mm
(0.004 in.)
Exhaust: 0.05 - 0.09 mm
(0.002 - 0.0035 in.)
0.15 mm
(0.006 in.)
Valve Springs New Service
Limit
Free Length: 49.8 mm (1.960 in.) 48.8 mm
(1.921 in.)
Squarness: 2Maximum 4Maximum
Spring Tension: 33 Kg @ 40.4 mm
(73 lbs. @ 1.59 in.)
Fig. 16 Valve Spring
Fig. 17 Valve Seat Reconditioning
Fig. 18 Install Valve Stem Seals
Fig. 19 Installed Valve Spring Position
ENGINE MOUNTS
RIGHT SIDE MOUNT
REMOVAL
concerns.
harness from engi ne mount.
verti cal fasteners and l oosen the hori zontal fastener.
Do Not remove the large nut on the end of the
core from the frame rail (Fig. 20).
from the engi ne si de bracket. Remove the engi ne
mount assembl y
INSTALLATION
(a) Engi ne mount to rai l fasteners to 68 Nm (50
ft. l bs.).
(b) The verti cal engi ne fastener to 102 Nm (75
ft. l bs.).
(c) The hori zontal fastener to 150 Nm (111 ft.
l bs.).
(2) I nstal l the purge duty sol enoi d and wi ri ng har-
ness to the engi ne mount.
Mount I nsul ator Adjustment.
FRONT MOUNT
REMOVAL
(1) Support the engi ne and transmi ssi on assembl y
bracket (Fi g. 21).
sary (Fi g. 21).
INSTALLATION
ti ghten fasteners i n thi s order:
(a) Ti ghten bol ts 2, 3, and 4 to 108 Nm (80 ft.
l bs.).
(b) Ti ghten bol ts 1 and 5 to 54 Nm (40 ft. l bs.).
(2) Engi ne mount adjustment. Refer to Engi ne
Mount I nsul ator Adjustment of thi s secti on.
Nm (105 i n. l bs.).
LEFT SIDE MOUNT
REMOVAL
wheel .
(2) Support the transmi ssi on wi th a transmi ssi on
jack.
mount.
(4) Remove the transmi ssi on mount fasteners and
remove mount.
INSTALLATION
Fig. 20 Engine MountRight
Fig. 21 Engine MountFront
(2) Ti ghten mount to transmi ssi on bol ts to 55 Nm
(40 ft. l bs.) (Fi g. 22).
Ti ghten through bol t to 75 Nm (55 ft. l bs.)
REAR MOUNT
jack so i t wi l l not rotate.
(4) Remove the four transmi ssi on mount fasteners
and remove the mount.
Refer to (Fi g. 23).
ENGINE MOUNT RUBBER INSULATORS
I nsul ator l ocati on on (ri ght si de) i s adjustabl e to
al l ow ri ght/l eft dri ve trai n adjustment i n rel ati on to
dri veshaft assembl y l ength. See Engi ne Mount
Adjustments i n thi s secti on.
Check and reposi ti on ri ght engi ne mount i nsul ator.
Adjust dri ve trai n posi ti on, i f requi red, for the fol l ow-
i ng condi ti ons:
Dri veshaft di stress: See Group 2, Suspensi on
and Dri veshafts.
Any front end structural damage (after repai r).
I nsul ator repl acement.
ENGINE ASSEMBLY
REMOVAL
to Group 14, Fuel System for procedure. Remove fuel
(3) Remove Ai r cl eaner and hoses.
(4) Remove battery cover, battery and battery tray,
wi th i ntegral vacuum reservoi r, from vehi cl e.
(5) Bl ock off heater hoses to rear heater assembl y,
i f equi pped.
(8) Remove fan modul e and radi ator. Refer to
Group 7, Cool i ng System for procedure.
(10) Di sconnect throttl e body l i nkage and vacuum
hoses from throttl e body.
(11) Remove accessory dri ve bel ts. Refer to Acces-
sory Dri ve System l ocated i n Group 7, Cool i ng Sys-
tem for procedure.
(12) Remove ai r condi ti oni ng compressor from
engi ne and set i t asi de.
(13) Di sconnect generator wi ri ng harness and
remove generator.
(14) Hoi st vehi cl e and remove axl e shafts. Refer to
Group 2, Dri veshaft for procedure.
(15) Remove ri ght and l eft i nner spl ash shi el ds.
(17) Remove front engi ne mount and bracket as an
assembl y.
(18) Remove rear transmi ssi on mount and bracket.
(19) Remove power steeri ng pump and bracket
assembl y.
(20) Remove wi ri ng harness and connectors from
front of engi ne.
(21) Remove bendi ng braces and i nstal l tool num-
ber 6910 on engi ne.
(22) Remove trans i nspecti on cover and mark fl ex-
pl ate to torque converter.
(23) Remove dri vepl ate to torque converter bol ts.
Fig. 22 Engine MountLeft
Fig. 23 Engine MountRear
Speci al Tool 6135 and cradl e Speci al Tool 6710 wi th
post Speci al Tool 6848 and adaptor Speci al Tool 6909
to be i nstal l ed under vehi cl e (Fi g. 24).
(27) Loosen cradl e engi ne mounts to al l ow move-
ment for posi ti oni ng onto engi ne l ocati ng hol es on the
engi ne. Lower vehi cl e and posi ti on cradl e mounts
transmi ssi on.
ENGINE AND TRANSMISSION i s on the cradl e.
(29) Remove ri ght engi ne mount assembl y and l eft
transmi ssi on mount through bol t. Refer to Engi ne
Mounts Secti on of thi s Group.
to al l ow for removal around body fl anges.
INSTALLATION
engi ne and transmi ssi on. I t may be necessary to
move the engi ne/transmi ssi on assembl y wi th the cra-
dl e for cl earance around body fl anges.
engi ne dol l y and cradl e Speci al Tool s 6135, 6710,
6848 and 6909.
(4) Remove Speci al tool s 6910 and i nstal l bendi ng
braces.
(5) Lower vehi cl e. I nstal l generator and wi ri ng
harness.
(6) Connect wi ri ng harness on the front of the
engi ne.
(7) I nstal l Ai r Condi ti oni ng Compressor.
(8) I nstal l power steeri ng pump and bracket and
accessory dri ve bel t. Refer to Group 7. Accessory
Dri ve Bel ts Secti on for i nstal l ati on procedure.
(9) Rai se vehi cl e and i nstal l axl e shafts. Refer to
Group 2, Dri veshafts for procedure.
(10) I nstal l transmi ssi on and engi ne mount and
bracket assembl i es. Refer to Engi ne Mounts i n thi s
secti on for procedure.
(12) I nstal l l eft and ri ght i nner spl ash shi el ds.
(13) Connect automati c transmi ssi on shi fter l i nk-
age. Refer to Group 21, Transmi ssi on for procedures.
(14) Lower vehi cl e and connect fuel l i ne and
heater hoses. Remove pl ugs from rear heater hoses
and i nstal l , i f equi pped.
throttl e body connecti ons and harnesses.
(17) I nstal l radi ator and fan modul e assembl y.
I nstal l radi ator hoses. Fi l l cool i ng system. Refer to
Group 7, Cool i ng for procedures.
(18) I nstal l battery tray, battery and cover.
ature i s reached.
CYLINDER HEAD COVER
REMOVAL
(2) Remove ai r i nl et resonator when removi ng l eft
head cover.
(3) When Removi ng l eft cyl i nder head cover,
remove di psti ck tube.
(4) When removi ng ri ght cyl i nder head cover
remove wi per uni t. Refer to Wi per Uni t Removal i n
Group 8K.
(5) When removi ng ri ght cyl i nder head cover,
remove accessory dri ve bel t. Refer to Accessory Dri ve
Bel t Removal i n Group 7.
Fig. 24 Positioning Engine Cradle Support Post
MountsTypical
(6) When removi ng ri ght cyl i nder head cover, di s-
connect generator wi ri ng and remove generator.
(7) Rel ocate spark pl ug wi res.
(8) Remove vacuum connecti ons.
(9) Remove rocker cover screws and remove cover
(Fi g. 25).
INSTALLATION
(1) Cl ean cyl i nder head and cover mati ng surfaces.
I nstal l new gasket.
(2) See (Fi g. 25) and appl y seal ant such as Mopar
Si l i cone Rubber Adhesi ve Seal ant to cover ends.
(3) I nstal l cover and ti ghten cover bol t washer and
gasket assembl y to 10 Nm (88 i n. l bs.).
(4) Reverse removal procedures for i nstal l ati on.
CAMSHAFT
REMOVAL
NOTE: SEE AUTO LASH ADJUSTER FUNCTION
CHECK BEFORE DISASSEMBLY
(1) I nstal l auto l ash adjuster retai ners (Fi g. 26).
(2) Remove di stri butor adaptor (Fi g. 27).
(3) When removi ng camshaft beari ng caps do not
remove the bol ts from the beari ng caps. Remove the
rocker arm, rocker shafts and beari ng cap as an
assembl y.
CAMSHAFT INSPECTION
(1) I nspect camshaft beari ng journal s for damage
and bi ndi ng (Fi g. 28). I f journal s are bi ndi ng, al so
check the cyl i nder head for damage. Al so check cyl -
i nder head oi l hol es for cl oggi ng.
(2) Front cyl i nder head camshaft check the tooth
surface of the di stri butor dri ve gear teeth of the cam-
shaft and repl ace i f abnormal wear i s evi dent (Fi g.
28).
(3) Check the cam surface for abnormal wear and
damage and repl ace i f defecti ve. Al so measure the
cam hei ght (Fi g. 28) and repl ace i f out of l i mi t, stan-
dard val ue i s 41.25 mm (1.624 i n.), wear limit i s
40.75 mm (1.604 i n.).
CAMSHAFT INSTALL
Lubri cate camshaft journal s and cams wi th engi ne
oi l and i nstal l camshaft on cyl i nder head.
Fig. 25 Rocker Cover
Fig. 26 Auto Lash Adjuster Retainers
ROCKER ARMS
INSTALL ROCKER ARM SHAFT ASSEMBLY
(1) Appl y Mopar Si l i cone Rubber Adhesi ve Seal ant
at beari ng cap ends as shown i n (Fi g. 29).
(2) I nstal l the rocker arm shaft assembl y maki ng
sure that the arrow mark on the beari ng cap and the
arrow mark on the cyl i nder head are i n the same
di recti on (Fi g. 29).
NOTE: The direction of arrow marks on the front
and rear assemblies are opposite to each other.
(3) Ti ghten beari ng cap bol ts i n the fol l owi ng order
to 10 Nm (85 i n. l bs.). Fi rst #3, then #2, #1 and #4.
(4) Repeat step 3 i ncreasi ng the torque to 20 Nm
(180 i n.l bs.).
(5) I nstal l di stri butor dri ve adaptor assembl y (Fi g.
30).
CAMSHAFT SEAL
CAMSHAFT END SEAL (PLUG) IN VEHICLE
SERVICE
(1) Remove ai r cl eaner assembl y from engi ne.
(2) Use a smal l punch and a hammer, careful l y
remove cam pl ug from cyl i nder head.
Fig. 27 Cylinder Heads and Camshafts
Fig. 28 Checking Camshafts
(3) Cl ean the area of the cyl i nder head where the
new cam pl ug wi l l be i nstal l ed.
(4) Appl y a l i ght coati ng of Mopar Si l i cone Rubber
Adhesi ve Seal ant to the outer di ameter of the NEW cam
pl ug.
(5) Usi ng a sui tabl e i nstal l i ng tool and a hammer,
i nstal l the new cam pl ug to a depth of 0.5 mm (0.020
i n.) bel ow the surface of the cyl i nder head.
(6) Repl ace ai r cl eaner assembl y.
CAMSHAFT OIL SEAL PLUG OUT OF
VEHICLE SERVICE
(1) Appl y l i ght coat of engi ne oi l to the camshaft
oi l seal l i p.
(2) I nstal l the oi l seal usi ng camshaft oi l seal
i nstal l er tool MD-998713 (Fi g. 31).
CAMSHAFT END SEAL (PLUG) SERVICE
OUT OF VEHICLE SERVICE
I nstal l end seal pl ug wi th Speci al Tool MD-998306
(Fi g. 32).
Fig. 29 Rocker Arm Shaft Direction
Fig. 30 Distributor Drive
Fig. 31 Camshaft Oil SealInstallation
Fig. 32 Camshaft End Seal PlugInstallation
CYLINDER HEAD
REMOVAL
(1) Remove ti mi ng bel t and camshaft sprockets.
See Ti mi ng Bel t i n thi s secti on for procedures.
(2) Remove cyl i nder head covers and rocker arms
and shafts. Refer to procedure outl i ned i n thi s sec-
ti on.
(3) Remove i ntake mani fol ds. Refer to I ntake and
Exhaust Mani fol ds, Group 11.
(4) Remove di stri butor.
(5) Remove exhaust mani fol ds and cross over Refer
to I ntake and Exhaust Mani fol ds, Group 11.
(6) Remove cyl i nder head bol ts i n sequence shown
i n (Fi g. 33) and remove cyl i nder head.
INSTALLATION
(1) Cl ean surfaces of head and bl ock, i nstal l head
gasket over l ocati ng dowel s.
(2) I nstal l head on l ocati ng dowel s.
(3) I nstal l 10 mm Al l en hex head bol ts wi th wash-
ers.
CAUTION: Attach the cylinder head bolt washer in
the direction shown in (Fig. 34).
(4) Ti ghten bol ts i n the order shown i n (Fi g. 35).
When ti ghteni ng the cyl i nder head bol ts, ti ghten
gradual l y, worki ng i n two or three steps and fi nal l y
ti ghten to speci fi ed torque of 108 Nm (80 ft. l bs.).
(5) I nstal l rocker arms and cyl i nder head covers.
(6) I nstal l camshaft sprockets and ti mi ng bel t.
(7) I nstal l exhaust mani fol ds and cross over pi pe.
(8) I nstal l di stri butor.
(9) I nstal l i ntake mani fol ds.
Fig. 33 Cylinder Head Bolt Removal Sequence
Fig. 34 Cylinder Head Bolt Washer
Fig. 35 Cylinder Head Bolt Tightening Sequence
TIMING BELT
REMOVAL
(1) Mark bel t runni ng di recti on for i nstal l ati on
(Fi g. 38).
(2) Loosen ti mi ng bel t tensi oner bol t (Fi g. 40) and
remove ti mi ng bel t.
(3) Remove crankshaft sprocket fl ange shi el d (Fi g.
36).
Fig. 36 Timing Belt System
CAMSHAFT SPROCKETS
To remove camshaft sprockets
1. Hol d camshaft sprocket wi th Spanner Tool
MB-990775 l oosen and remove bol t and washer (Fi g.
39).
2. Remove camshaft sprocket from camshaft.
To i nstal l camshaft sprockets
3. Pl ace camshaft sprocket on camshaft.
4. I nstal l bol t and washer to camshaft. Usi ng
Spanner Tool MB-990775 hol d camshaft sprocket and
torque bol t to 95 Nm (70 ft. l bs.) (Fi g. 39).
TIMING BELT TENSIONER
(1) I nstal l ti mi ng bel t tensi oner and tensi oner
spri ng.
(2) Hook spri ng upper end to water pump pi n and
l ower end to tensi oner bracket wi th hook out (Fi g.
40).
(3) Turn ti mi ng bel t tensi oner countercl ockwi se
ful l travel i n adjustment sl ot and ti ghten bol t to tem-
porari l y hol d thi s posi ti on (Fi g. 41).
INSTALLATIONTIMING BELT
(1) I nstal l ti mi ng bel t on crankshaft sprocket and
keep bel t ti ght on tensi on si de (Fi g. 38). I nstal l bel t
on the front (radi ator si de) camshaft sprocket. I nstal l
bel t on the water pump pul l ey, rear camshaft
sprocket and fi nal l y on the ti mi ng bel t tensi oner.
(2) Rotate the front camshaft sprocket i n opposi te
di recti on to take up bel t sl ack. Check that al l ti mi ng
marks are al i gned (Fi g. 38).
(3) I nstal l crankshaft sprocket fl ange (Fi g. 36).
(4) Loosen tensi oner bol t and al l ow spri ng to ten-
si on ti mi ng bel t.
Fig. 38 Timing Belt Engine Sprocket Timing
Fig. 39 Camshaft Sprockets
(5) Turn crankshaft two ful l turns i n cl ockwi se
di recti on. Turn smoothly and in clockwise direc-
tion ONLY.
(6) Al i gn the ti mi ng marks on the sprockets and
ti ghten the ti mi ng bel t tensi oner l ocki ng bol t to 25
(7) Reassembl y bel t covers, engi ne bracket, i nsul a-
tor, crankshaft pul l eys, accessori es and accessory
dri ve bel ts i n reverse order.
OIL PAN
Oi l pan to crankcase seal i ng i s provi ded wi th
Mopar Si l i cone Rubber Adhesi ve Seal ant or equi va-
l ent gasket materi al . See Form-I n-Pl ace Gaskets i n
Standard Servi ce Procedures.
(1) Appl y seal ant as shown i n (Fi g. 42).
(2) I nstal l pan and ti ghten screws to 6 Nm (50 i n.
l bs.) i n sequence shown i n (Fi g. 43).
Fig. 41 Positioning Belt Tensioner
Fig. 43 Oil Pan Screw Tightening Sequence
Fig. 40 Timing Belt Tensioner
(1) I denti fy and mark pi stons. The pistons are
not interchangeable frombank to bank (Fi g. 45).
(2) Pi stons wi th the l etter R and arrow toward the
front of engi ne are to be i nstal l ed i n cyl i nders 1-3-5.
Pi stons wi th the l etter L and arrow toward the front
of engi ne are to be i nstal l ed i n cyl i nders 2-4-6.
(3) Mark connecti ng rod and cap wi th cyl i nder
number (Fi g. 46).
(4) Remove pi ston ri ngs (Fi g. 47).
FITTING PISTONS
Measure approxi matel y 2 mm (0.080 i n.) above the
bottom of the pi ston ski rt and across the thrust face
(Fi g. 48). See Bori ng Cyl i nder i n Cyl i nder Bl ock.
Fig. 44 Pistons and Connecting Rods
Fig. 45 Mark Pistons
Fig. 46 Mark Matching Parts
Fig. 47 Remove Piston Rings
posi ti oni ng at l east 16 mm (0.63 i n.) from bottom of
Refer to Pi ston Ri ng Speci fi cati on Chart.
(2) Check pi ston ri ng to groove cl earance (Fi g. 50).
(1) The No. 1 and No. 2 pi ston ri ngs have a di ffer-
ent cross secti on. I nstal l ri ngs wi th manufacturers
mark and si ze mark faci ng up, to the top of the pi s-
ton (Fi g. 51).
order:
Ring Position Ring Gap Ring Gap Wear
Limit
Groove Clearance Maximum Groove
Clearance
Upper Ring 0.30 - 0.45 mm
(0.012 - 0.018 in.)
0.8 mm (0.031 in.) 0.05 - 0.09 mm
(0.002 - 0.0035 in.)
0.10 mm (0.004 in.)
Intermediate Ring 0.25 - 0.40 mm
(0.010 - 0.016 in.)
0.8 mm (0.031 in.) 0.02 - 0.06 mm
(0.0007 - 0.002 in.)
0.10 mm (0.004 in.)
Oil Control Ring 0.30 - 0.90 mm
(0.012 - 0.035 in.)
1.0 mm (0.039 in.) Oil Ring Side Rails Must Be Free To Rotate
After Assembly
Fig. 48 Piston Clearance and Wear
Fig. 49 Check Gap on Piston Rings
Fig. 50 Piston Ring Clearance
Fig. 51 Piston RingInstallation
(2) I nstal l the si de rai l by pl aci ng one end between
the pi ston ri ng groove and the expander. Hol d end
fi rml y and press down the porti on to be i nstal l ed
unti l si de rai l i s i n posi ti on. Do not use a piston
ring expander (Fi g. 52).
si de rai l .
ri ng (Fi g. 53).
(5) Posi ti on pi ston ri ng end gaps as shown i n (Fi g. 54).
(6) Posi ti on oi l ri ng expander gap at l east 45 from
the si de rai l gaps but not on the pi ston pi n center or
on the thrust di recti on.
(7) Connecti ng rod front mark 72 must al ways face
forward, toward ti mi ng bel t end. (Fi g. 55)
(8) I nstal l the pi ston and connecti ng rod assembl y
i nto there respecti ve bore from the cyl i nder bl ock top.
CAUTION: Piston assemblies are not to be inter-
changed from bank to bank.
(9) Check al i gnment marks made duri ng di sassem-
bl y and that beari ng posi ti on notches new or used
are on the same si de as shown i n (Fi g. 56).
Fig. 52 Side RailInstallation
Fig. 53 Installing Upper and Intermediate Rings
Fig. 55 Identify Piston and Rod Assembly for
Cylinder Installation
Fig. 56 Connecting Rod and Cap
CRANKSHAFT
REMOVAL
(1) Remove front mounted oi l pump assembl y and
gasket (Fi g. 57) and (Fi g. 58).
(2) Remove rear oi l seal retai ner and seal as
assembl y (Fi g. 59).
(3) Rel ease mono-bl ock mai n beari ng cap bol ts
evenl y. Remove l ower beari ng shel l s and i denti fy for
reassembl y.
(4) Li ft out crankshaft and remove upper thrust
washers from each si de of number three mai n bear-
i ng i n the crankcase (Fi g. 57).
Fig. 57 Crankshaft and Cylinder Block
Fig. 58 Oil Pump Assembly
Fig. 59 Rear Seal Assembly
CRANKSHAFT BEARINGSINSTALLATION
(1) I nstal l upper mai n beari ng shel l s maki ng cer-
tai n oi l hol es are i n al i gnment, and beari ng tabs seat
i n bl ock tabs. Al l upper beari ngs have oi l grooves
(Fi g. 60).
(2) THRUST BEARINGS. Crankshaft thrust
beari ngs (washers) are i nstal l ed at journal #3 sepa-
ratel y from the radi al beari ngs. Thrust beari ngs
shown i n (Fi g. 60) are di fferent, one has end posi ti on-
i ng tabs, whi l e the other i s pl ai n. One pair of each
thrust washers are i nstal l ed i nto the bl ock and one
pair i nto the mai n beari ng cap (Fi g. 60).
(3) Appl y a thi n fi l m of grease to pl ai n si de of
thrust washers and posi ti on them on each si de of
number three mai n beari ng. Grooved surface towards
crankshaft.
crankshaft.
(5) I nstal l l ower mai n beari ng shel l s wi thout oi l
grooves i n mono-bl ock cap.
(6) I nstal l one pai r of thrust washers i n cap. Refer
to Thrust Beari ngs (Fi g. 60).
(7) Careful l y i nstal l beari ng cap wi th arrows (Fi g.
61) toward ti mi ng bel t end.
(8) Oi l the beari ng cap bol t threads, i nstal l and
ti ghten bol ts progressi vel y i n sequence shown i n (Fi g.
61) to 80 Nm (60 ft. l bs.) torque.
Fig. 60 Main BearingsInstallation
REAR CRANKSHAFT SEAL
REAR CRANKSHAFT SEAL RETAINER
(1) I nstal l rear crankshaft oi l seal i n housi ng wi th
Speci al Tool MD-998718 (Fi g. 62).
or equi val ent to oi l seal housi ng (Fi g. 63) per proce-
dure detai l ed i n form-i n-pl ace gasket secti on i n Stan-
dard Servi ce Procedures.
(3) Appl y l i ght coati ng of engi ne oi l to the enti re
ci rcumference of oi l seal l i p.
(4) I nstal l seal assembl y on cyl i nder bl ock and
ti ghten bol ts to 12 Nm (104 i n. l bs.)
FRONT CRANKSHAFT OIL SEAL
(1) I nstal l oi l pump gasket and oi l pump case (Fi g.
65) and (Fi g. 64).
CAUTION: Install bolts, depending on length in
locations shown in (Fig. 64).
(2) Usi ng front crankshaft oi l seal i nstal l er Speci al
Tool MD-998717 i nstal l oi l seal i n oi l pump (Fi g. 65).
Fig. 62 Rear Crankshaft Oil SealInstallation
Fig. 61 Crankshaft Main Bearing Cap
Fig. 63 Apply Sealant to Oil Seal Housing
OIL PUMP
REMOVAL
1. Remove accessory dri ve bel ts. Refer to Accessory
Dri ve Bel ts Group 7, Cool i ng System.
2. Remove Ti mi ng Bel t. Refer to procedure i n thi s
secti on.
3. Remove 5 bol ts that attach oi l pump to bl ock
(Fi g. 66).
INSTALLATION
(1) Cl ean bl ock and pump surfaces.
(2) I nstal l new gasket (Fi g. 67) make sure correct
l ength bol ts are used (Fi g. 66).
(3) Torque bol ts to 13 Nm (120 i n. l bs.).
OIL FILTER AND ADAPTOR
(1) Check the oi l fi l ter mounti ng surface. The sur-
face must be smooth, fl at and free of debri s or ol d
pi eces of rubber (Fi g. 68).
(2) Check adaptor for cracks and oi l l eaks.
CAUTION: When servicing the oil filter avoid
deforming the filter. Install the remove/install tool
band strap against the can-to-base lock seam. The
lock seam joining the can-to-base is reinforced by
the base plate.
(3) Usi ng Tool C-4065, turn fi l ter countercl ockwi se
to remove from base. Properl y di scard fi l ter.
(4) Wi pe base cl ean, then i nspect gasket contact
surface.
(5) Lubri cate gasket of new fi l ter wi th cl ean
engi ne oi l .
Fig. 64 Oil Pump
Fig. 66 Oil Pump Assembly
Fig. 67 Oil Pump Components
(6) I nstal l new fi l ter unti l gasket contacts base.
Ti ghten fi l ter 1 turn or 20 Nm (15 ft. l bs.). Use fi l ter
wrench i f necessary.
(7) Start engi ne and check for l eaks.
ROCKER ARMS AND SHAFTS
(1) Check rocker arms for wear or damage (Fi g.
69). Repl ace as necessary. Al so see Auto Lash
Adjuster.
ROCKER ARM SHAFTS
The rocker arm shaft i s hol l ow and i s used as a
l ubri cati on oi l duct. The rocker arm shaft on the
inlet si de has a 3 mm (0.188 i n.) di ameter oi l pas-
sage hol e from the cyl i nder head. The exhaust si de
does not have thi s oi l passage (Fi g. 70).
(1) Check the rocker arm mounti ng porti on of the
shafts for wear or damage. Repl ace i f heavi l y dam-
aged or worn.
(2) Check oi l hol es for cl oggi ng wi th smal l wi re,
cl ean as requi red (Fi g. 70).
REASSEMBLE
(1) Al i gn the camshaft beari ng caps wi th arrows
(dependi ng on cyl i nder bank) di rected as shown i n
(Fi g. 71) and i n numeri cal order. I denti fy number one
beari ng cap number one and number four caps are
si mi l ar (Fi g. 72).
(2) I nstal l rocker shafts so that beari ng cap num-
ber one wi th end notches posi ti oned as shown i n (Fi g.
72) that the machi ned porti on of the rocker shaft i s
faci ng down.
(3) I nstal l attachi ng bol ts to retai n assembl y.
ASSEMBLE ROCKER ASSEMBLY
I nstal l the rocker arms, beari ng caps and spri ngs.
Springs are the same and can be used at all
locations on the rocker arm shafts (Fi g. 71) and
(Fi g. 73). I nsert bol ts i n number four beari ng cap to
retai n assembl y.
Fig. 68 Oil Filter and Adaptor
Fig. 69 Inspect Rocker Arms
Fig. 70 Rocker Arm Shaft Identification
Fig. 71 Camshaft Bearing Caps Position
TIMING BELT
INSPECTION
(1) Remove the upper front outer ti mi ng bel t cover
by l ooseni ng the three attachi ng bol ts (Fi g. 75).
(2) I nspect both si des of the ti mi ng bel t dri ve &
back. Repl ace bel t i f any of the fol l owi ng condi ti ons
exi st:
Rubber back si de i s gl ossy, hardened back wi th-
out resi l i ence and l eaves no i ndent when pressed
wi th fi ngernai l .
Cracks on rubber back.
Cracks or peel i ng of canvas.
Cracks on ri b root.
Mi ssi ng teeth.
The si des are normal i f they are sharp as i f cut
by a kni fe (Fi g. 74).
NOTE: If none of the above conditions are seen on
the belt, the belt cover can be installed.
CYLINDER HEAD
(1) Before cl eani ng, check for l eaks, damage and
cracks.
(2) Cl ean cyl i nder head and oi l passages.
(3) Check cyl i nder head for fl atness (Fi g. 76).
(4) Cyl i nder head must be fl at wi thi n:
Standard di mensi on = l ess than 0.05 mm (.002
i n.)
Servi ce Li mi t = 0.2 mm (.008 i n.)
Gri ndi ng Li mi t = Maxi mum of 0.2 mm (.008 i n.)
i s permi tted.
Fig. 73 Rocker Arm and Shafts
Fig. 72 Number One Camshaft Bearing Cap
CAUTION: This is a combined total dimension of
stock removal from cylinder head if any and block
top surface.
CYLINDER BORE
INSPECTION
(1) Measure the cyl i nder bore at three l evel s i n
di recti ons A and B (Fi g. 77). Top measurement
shoul d be 12 mm (0.50 i n.) down and bottom mea-
surement shoul d be 10 mm (0.38 i n.) up.
(2) Standard bore di mensi on: 91.1 mm (3.587 i n.)
(3) Maxi mum out-of-round or taper: 0.02 mm
(0.0008 i n.).
OIL PUMP
(1) Check oi l pump case for damage. Remove rear
oi l pump cover.
(2) Remove pump rotors and i nspect case for exces-
si ve wear.
(3) Measure cl earance between case and i nner
rotor (Fi g. 78).
(4) I nsert the rotor i nto the oi l pump case and
measure cl earance between outer rotor and case wi th
a feel er gauge (Fi g. 79). Repl ace i f out of speci fi ca-
ti ons.
Fig. 74 Timing Belt Inspection
Fig. 76 Check Cylinder Head
(5) Usi ng a feel er gauge, measure cl earance between
i nner rotor ti p and outer rotor (Fi g. 80). Cl earance spec-
i fi cati on i s: 0.06 - 0.18 mm (0.003 - 0.007 i n.). Repl ace
both rotors i f not wi thi n speci fi cati ons
(6) Pl ace a strai ghtedge across face of pump hous-
i ng (Fi g. 81). Cl earance speci fi cati on i s: 0.04 - 0.10
mm (0.0015 - 0.0039 i n.). Repl ace oi l pump assembl y
i f not wi thi n speci fi cati ons.
OIL RELIEF PLUNGER
(1) Check that the oi l rel i ef pl unger sl i des
smoothl y.
(2) Check for broken rel i ef spri ng.
ADJ USTMENTS
ENGINE MOUNTS
screws.
suri ng.
fol l owi ng order:
150 Nm (110 ft. l bs.).
ft. l bs.).
Fig. 78 Inner Rotor to Case
Fig. 79 Measuring Clearance Between Outer Rotor
and Case
SPECIFICATIONS
3. 0L ENGINE
Type . . . . . . . . . . . . . . . . . . . . . . . . .60 V-6 SOHC
Number of Cyl i nders . . . . . . . . . . . . . . . . . . . . . . .6
Bore . . . . . . . . . . . . . . . . . . . . .91.1 mm (3.587 i n.)
Stroke . . . . . . . . . . . . . . . . . . . . .76 mm (2.992 i n.)
Compressi on Rati o. . . . . . . . . . . . . . . . . . . . .8.85:1
Di spl acement . . . . . . . . . . . . . .3.0L (181 Cubi c i n.)
Fi ri ng Order . . . . . . . . . . . . . . . . . . . .123456
Basi c I gni ti on Ti mi ng . . . . . . . . .Refer to Emi ssi on
Control I nformati on Label on Vehi cl e
Compressi on Pressure . . . . . . . . . . . . . . .1227 kPa
(178 psi ) @ 250 RPM
Maxi mum Vari ati on Between Cyl i nders . . . . . .25%
Valve Timing
I ntake Val veOpen . . . . . . . . . . . . . . . . .19 BTDC
I ntake Val veCl osed . . . . . . . . . . . . . . . .59 ABDC
Exhaust Val veOpen. . . . . . . . . . . . . . . .59 BBDC
Exhaust Val veCl osed . . . . . . . . . . . . . . .19 ATDC
Cylinder Block
Cyl i nder Bore Di ameter . . . . . .91.1 mm (3.587 i n.)
Top Surface Fl atness . . . . . . . .0.05 mm (0.002 i n.)
Servi ce Li mi t. . . . . . . . . . . . .0.1 mm (0.0039 i n.)
Gri ndi ng Li mi t of Top Surface*. . . . . . . . . .0.2 mm
(0.008 i n.)
*I ncl udes/Combi ned wi th cyl i nder Head Gri ndi ng
Pistons
Pi ston Di ameter . . . . . . . . . . . . . . . . .91.06 - 91.09
Pi ston to Cyl i nder Cl earance . . . . . .0.03 - 0.05 mm
(0.0012 - 0.002 i n.)
Pi ston Ri ng End Gap No. 1 . . . . . .0.30 - 0.45 mm
(0.012 - 0.018 i n.)
Servi ce Li mi t. . . . . . . . . . . . . .0.8 mm (0.031 i n.)
Pi ston Ri ng End Gap No. 2 . . . . . .0.45 - 0.60 mm
(0.018 - 0.024 i n.)
Pi ston Ri ng End Gap Oi l Control . .0.20 - 0.60 mm
(0.008 - 0.024 i n.)
Ri ng Si de Cl earance No. 1 . . . . . .0.030 - 0.090 mm
(0.002 - 0.0035 i n.)
Ri ng Si de Cl earance No. 2 . . . . . .0.040 - 0.085 mm
(0.0016 - 0.0033 i n.)
Oversi ze Servi ce Pi stons . . . . . . . . .0.25 - 0.50 mm
(0.010 - 0.020 i n.),
0.75 - 1.00 mm (0.030 - 0.039 i n.)
Connecting Rods
(0.0007 - 0.0014 i n.)
Si de Cl earance . . . . . . . . . . . . . . . .0.10 - 0.25 mm
(0.004 - 0.010 i n.)
Wear Li mi t . . . . . . . . . . . . . . . . .0.4 mm (0.015 i n.)
LengthCenter to Center . . . . . . .140.9 - 141.0 mm
(5.547 - 5.551 i n.)
Paral l el i smTwi st . . . . . . . . . .0.05 mm (0.0019 i n.)
Torsi on . . . . . . . . . . . . . . . . . . .0.1 mm (0.0039 i n.)
Crankshaft
Mai n Journal Di ameter . . . . . . .59.980 - 60.0 mm
(2.361 - 2.362 i n.)
Connecti ng Rod
(1.968 - 1.969 i n.)
Out-of-Round (Max.). . . . . . . . .0.03 mm (0.001 i n.)
Taper (Max.) . . . . . . . . . . . . .0.005 mm (0.0002 i n.)
Mai n and Rod
Beari ng Cl earance . . . . . . . . . . .0.018 - 0.036 mm
(0.0007 - 0.0014 i n.)
Undersi ze Servi ce
Beari ngs . . . . . . . . . . . . . . . .0.25 - 0.50 - 0.75 mm
(0.010 - 0.020 - 0.030 i n.)
End Pl ay . . . . . . .0.05 - 0.25 mm (0.002 - 0.010 i n.)
Cylinder Head
Fl atness of Gasket Surface . . . .0.05 mm (0.002 i n.)
Gri ndi ng Li mi t of
Gasket Surface . . . . . . . . . . . . .0.2 mm (0.008 i n.)
Angl eI ntake and Exhaust . . . . . . . . . .44 - 44.3
Contact Wi dth . . . . . . . . . . . . . . . . . . .0.9 - 1.3 mm
(0.035 - 0.051 i n.)
Si nkageServi ce Li mi t . . . . . . . .0.2 mm (0.078 i n.)
Gui de Bore Di ameter (Std) . . . . . . .7.95 - 7.98 mm
(0.313 - 0.314 i n.)
Valves
Face Angl e . . . . . . . . . . . . . . . . . . . . . .45 - 45 30
Head Di ameter I ntake . . . . . . . . .48.64 - 48.90 mm
(1.915 - 1.925 i n.)
Head Di ameter Exhaust . . . . . . .40.01 - 40.26 mm
(1.575 - 1.585 i n.)
Length I ntake (Overal l ) . . . . .103.0 mm (4.055 i n.)
Length Exhaust (Overal l ). . . .102.7 mm (4.043 i n.)
Val ve Margi nI ntake . . . . . . . . .1.2 mm (0.047 i n.)
Val ve Margi nExhaust . . . . . . . .2.0 mm (0.079 i n.)
Val ve Stem Ti p Hei ght . . . . . .49.02 mm (1.929 i n.)
Stem Di ameterI ntake . . . . . . . .7.960 - 7.975 mm
(0.313 - 0.314 i n.)
Stem Di ameterExhaust . . . . . . .7.930 - 7.950 mm
(0.312 - 0.3125 i n.)
Stem-to-Gui de Cl earanceI ntake. . .0.03 - 0.06 mm
(0.001 - 0.002 i n.)
Stem-to-Gui de Cl earance
Exhaust . . . . . . . . . . . . . . . . . . . . .0.05 - 0.09 mm
(0.0019 - 0.003 i n.)
Valve Guide
Overal l LengthI ntake . . . . . . . .44 mm (1.732 i n.)
Overal l LengthExhaust . . . . . . .48 mm (1.889 i n.)
Outsi de Di ameter . . . . . . . . . . .13.055 - 13.065 mm
(0.514 - 0.5143 i n.)
I nsi de Di ameter . . . . . . . . . . . . . .8.000 - 8.018 mm
(0.314 - 315 i n.)
Valve Springs
Servi ce Li mi t. . . . . . . . . . . .48.8 mm (1.9213 i n.)
Loaded Hei ght . . . . . . . . . . . . . . .40.4 mm @ 33 kg
(1.59 i n. @73 l bs.)
Perpendi cul ari tyI ntake and Exhaust . . .2 (Max.)
Servi ce Li mi t. . . . . . . . . . . . . . . . . . . . .4 (Max.)
Oil Pump
Cl earance Over Rotors (Max.).0.077 mm (0.003 i n.)
I nner Rotor Thi ckness (Mi n.) .18.92 mm (0.744 i n.)
Outer Rotor (Oil Pump)
Cl earance (Max.) . . . . . . . . . . .0.19 mm (0.007 i n.)
Di ameter (Mi n.) . . . . . . . . . . .82.45 mm (3.246 i n.)
Thi ckness (Mi n.). . . . . . . . . . .18.92 mm (0.744 i n.)
Ti p Cl earance Between Rotors (Max.) . . .0.150 mm
(0.0068 i n.)
Oil Pressure
At Curb I dl e Speed* . . . . . . . . . . .68.9 kPa (10 psi )
At 3000 rpm . . . . . . . . .310 - 517 kPa (45 - 75 psi )
TORQUE CHART 3. 0L
DESCRIPTION TORQUE
Camshaft Bearing Cap
Bol ts. . .Refer to procedure outl i ned i n thi s secti on.
Bol ts . . . . . . . . . . . . . . . . . . . . .27 Nm (20 ft. l bs.)
Timing Belt Cover
Outer to I nner Attachi ng Bol ts . . . . . . . . . .4.5 Nm
(40 i n. l bs.)
I nner Cover to Head/Oi l Pump Bol ts . . . . .12 Nm
(105 i n. l bs.)
Camshaft Sprocket
Bol t . . . . . . . . . . . . . . . . . . . . . .95 Nm (70 ft. l bs.)
Connecting Rod Cap
Bol ts . . . . . . . . . .27 Nm (20 ft. l bs.) Pl us 1/4 Turn
M8 Bedpl ate Bol ts . . . . . . . . .34 Nm (250 i n. l bs.)
M11 Mai n Cap Bol ts . . . . . . . . . . . . . . . . . .41 Nm
Crankshaft Vibration Damper
Bol t . . . . . . . . . . . . . . . . . . . .135 Nm (100 ft. l bs.)
DESCRIPTION TORQUE
Cylinder Head
Bol ts . . . . . . . .Refer To Cyl i nder Head I nstal l ati on
Cylinder Head Cover
Bol ts . . . . . . . . . . . . . . . . . . . .12 Nm (105 i n. l bs.)
Engine Mount Bracket
Bol ts . . . . . . . . . . . . . . . . . . . . .41 Nm (30 ft. l bs.)
Engine MountFront and Rear
Through Bol t . . . . . . . . . . . . . . .61 Nm (45 ft. l bs.)
Bol ts . . . . . . . . . . . . . . . . . . . .23 Nm (200 i n. l bs.)
Bol ts . . . . . . . . . . . . . . . . . . . .12 Nm (105 i n. l bs.)
Intake Manifold
Bol ts . . . . . . . . . . . . . . . . . . . . .27 Nm (20 ft. l bs.)
Oil Filter to Engine Block Adapter
Bol ts . . . . . . . . . . . . . . . . . . . . .55 Nm (40 ft. l bs.)
Oil Filter
Fi l ter . . . . . . . . . . . . . . . . . . . . .20 Nm (15 ft. l bs.)
Oil Pan
Oi l Pan Bol ts . . . . . . . . . . . . .12 Nm (105 i n. l bs.)
Oil Pump Attaching
Bol ts . . . . . . . . . . . . . . . . . . . .15 Nm (130 i n. l bs.)
Oi l Pump Cover Fastener . . . . .9 Nm (104 i n. l bs.)
Oi l Pump Pi ck-up Tube Bol t . .28 Nm (250 i n. l bs.)
Oi l Pump Rel i ef Val ve Cap . . . .49 Nm (36 ft. l bs.)
Spark Plugs
Pl ugs . . . . . . . . . . . . . . . . . . . . .28 Nm (20 ft. l bs.)
Thermostat Housing
Bol ts . . . . . . . . . . . . . . . . . . . .23 Nm (200 i n l bs.)
Timing Belt Tensioner
Bol t . . . . . . . . . . . . . . . . . . . . . .28 Nm (20 ft. l bs.)
Timing Belt Tensioner Pulley Assembly
Bol t . . . . . . . . . . . . . . . . . . . . . .41 Nm (30 ft. l bs.)
Water Pump Mounting
Bol ts . . . . . . . . . . . . . . . . . . . .12 Nm (105 i n. l bs.)
SPECIAL TOOLS
3. 0L ENGINE
Dolly 6135
Cradle 6710
Adaptor 6909
Adaptor 6910
Camshaft End Plug Installer MD-998306
Valve Stem Seal Installer MD-998729
Rear Crankshaft Seal Installer MD-998718
Front Crankshaft Seal Installer MD-998717
Oil Filter Wrench C-4065
Spanner Camshaft Sprocket MB-990775
3.3/3.8L ENGINE
INDEX
page page
HYDRAULIC TAPPETS . . . . . . . . . . . . . . . . . . . . 94
SERVICE PROCEDURES
FITTING CONNECTING ROD BEARINGS . . . . . . 97
FITTING MAIN BEARINGS . . . . . . . . . . . . . . . . . 98
FITTING PISTONS AND RINGS . . . . . . . . . . . . . 97
MEASURING TIMING CHAIN FOR STRETCH . . . 96
VALVE SERVICE RECONDITION . . . . . . . . . . . 100
VALVE TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . 96
CAMSHAFT BEARINGS . . . . . . . . . . . . . . . . . . 114
CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
CRANKSHAFT DAMPER . . . . . . . . . . . . . . . . . 106
CRANKSHAFT OIL SEALFRONT . . . . . . . . . . 117
CRANKSHAFT OIL SEALREAR . . . . . . . . . . . 118
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . 116
CYLINDER HEAD COVER . . . . . . . . . . . . . . . . 107
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . 108
ENGINE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . 104
ENGINE MOUNTS . . . . . . . . . . . . . . . . . . . . . . 102
ENGINE OIL GALLERY PLUGS . . . . . . . . . . . . . 119
OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
PISTON AND CONNECTING ROD . . . . . . . . . . 115
ROCKER ARMS AND SHAFT ASSEMBLY . . . . . 106
TAPPET REMOVAL . . . . . . . . . . . . . . . . . . . . . . 110
TIMING CHAIN COVER . . . . . . . . . . . . . . . . . . . 111
TIMING CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . 112
VALVE STEM SEALS OR SPRINGS,
CYLINDER HEAD NOT REMOVED . . . . . . . . 106
VALVES AND VALVE SPRINGS . . . . . . . . . . . . 109
WIPER UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . 102
HYDRAULIC TAPPETS . . . . . . . . . . . . . . . . . . . 120
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . 120
ENGINE BLOCK AND BORE . . . . . . . . . . . . . . . 121
OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
ADJUSTMENTS
ENGINE MOUNTS . . . . . . . . . . . . . . . . . . . . . . 123
SPECIFICATIONS
3.3/3.8L ENGINE . . . . . . . . . . . . . . . . . . . . . . . 123
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . 125
SPECIAL TOOLS
3.3/3.8L ENGINE . . . . . . . . . . . . . . . . . . . . . . . 127
rear of the cyl i nder bl ock just bel ow the cyl i nder
head (Fi g. 1).
The l ubri cati on system i s a ful l fl ow fi l trati on pres-
sure feed type. Oi l from the oi l pan i s pumped by a
i nternal gear type oi l pump di rectl y coupl ed to the
crankshaft. The pressure i s regul ated by a rel i ef
val ve l ocated i n the chai n case cover. The oi l i s
pumped through an oi l fi l ter and feeds a mai n oi l
gal l ey. Thi s oi l gal l ery feeds oi l under pressure to the
mai n and rod beari ngs, camshaft beari ngs. Passages
i n the cyl i nder bl ock feed oi l to the hydraul i c l i fters
and rocker shaft brackets whi ch feeds the rocker arm
pi vots (Fi g. 2).
ENGINE COMPONENTS
ENGINE: The 3.3L (201 Cubi c I nches) and 3.8L
(231 Cubi c I nches) di spl acement engi nes are 60 V
type si x cyl i nder power pl ants wi th cast i ron cyl i nder
bl ocks and al umi num cyl i nder heads (Fi g. 3). Fi ri ng
order for these engi nes i s 1-2-3-4-5-6. Hi gh turbu-
l ence cyl i nder heads al l ow a 8.9-1 compressi on rati o.
CRANKSHAFT: The nodul ar i ron crankshaft i s
supported by four mai n beari ngs, wi th number two
bei ng the thrust beari ng. Crankshaft end seal i ng i s
provi ded by front and rear rubber seal s.
PISTONS: The pi stons are cast al umi num al l oy.
Three ri ngs are used. Pi ston pi ns, press fi tted i nto
pl ace, joi n the pi stons to forged steel connecti ng rods.
CAMSHAFT: The nodul ar i ron camshaft i s
mounted i n four steel backed babbi tt beari ngs. A
thrust pl ate l ocated i n front of the fi rst beari ng, and
bol ted to the bl ock, control s end pl ay. Si l ent ti mi ng
chai n dri ves the camshaft. Thi s chai n i s encl osed by
a cast al umi num cover whi ch al so carri es a front
NS 3. 3/3. 8L ENGINE 9 - 93
crankshaft seal , provi des front oi l pan cl osure, water
pump mounti ng.
CYLINDER HEADS: Cyl i nder heads are desi gned
to create hi gh fl ow combusti on chambers to i mprove
performance, whi l e mi ni mi zi ng the change to the
burn rate of the chamber. Val ve seat and gui des are
i nserts. A steel fl anged composi ti on type gasket i s
used between head and bl ock.
CYLINDER HEAD COVERS: The covers are
seal ed wi th steel rei nforced si l i con rubber gaskets.
tuned two-pi ece semi -permanent mol d al umi num
casti ng wi th i ndi vi dual pri mary runners l eadi ng from
a pl enum to the cyl i nders. The mani fol d i s desi gned
to boost torque i n the 3600 rpm range and contri b-
utes to the engi nes broad, fl at torque curve, whi ch
was desi red for excel l ent engi ne tractabi l i ty, response
and usabl e power output.
The i ntake mani fol d i s al so cored wi th upper l evel
EGR passages for bal anced cyl i nder to cyl i nder EGR
di stri buti on.
VALVE TRAIN: Val ve trai n desi gn i ncorporates
the use of hydraul i c rol l er tappets. Rocker arms are
i nstal l ed on a rocker arm shaft attached to the cyl i n-
der head wi th four bol ts and retai ners. Vi ton val ve
stem seal s provi de val ve seal i ng. Conventi onal type
pushrods, retai ners and val ve stem l ocks are used.
Uni que beehi ve styl e val ve spri ng are used wi th
l i ghtwei ght retai ners for i mproved hi gh RPM perfor-
mance.
EXHAUST MANIFOLDS: Exhaust mani fol ds are
l og type wi th a crossover and i s attached di rectl y to
the cyl i nder heads.
HYDRAULIC TAPPETS
The val ve trai n i ncl udes rol l er tappet assembl i es,
al i gni ng yokes and yoke retai ner.
Rol l er tappet al i gnment i s mai ntai ned by machi ned
fl ats on tappet body bei ng fi tted i n pai rs i nto si x
Fig. 2 Engine Oiling System
9 - 94 3. 3/3. 8L ENGINE NS
al i gni ng yokes. The yokes are secured by an al i gn-
ment yoke retai ner (Fi g. 4).
PRELIMINARY STEP TO CHECKING THE
HYDRAULIC TAPPETS
Before di sassembl i ng any part of the engi ne to cor-
rect tappet noi se, read the oi l pressure at the gauge.
I nstal l a rel i abl e gauge at pressure sendi ng uni t i f
vehi cl e has no oi l pressure gauge and check the oi l
l evel i n the oi l pan. The pressure shoul d be between
30 and 80 psi (206.8 to 551.6 kPa) at 2000 rpm.
The oi l l evel i n the pan shoul d never be above the
MAX mark on di psti ck, or bel ow the MI N mark.
Ei ther of these two condi ti ons coul d be responsi bl e
for noi sy tappets. Oil Level Check: stop engine
after reaching normal operating temperature.
Al l ow 5 mi nutes to stabi l i ze oi l l evel , check di psti ck.
OIL LEVEL TOO HIGH
I f oi l l evel i s above the MAX mark on di p sti ck, i t
i s possi bl e for the connecti ng rods to di p i nto the oi l
whi l e engi ne i s runni ng and create foam. Foam i n oi l
pan woul d be fed to the hydraul i c tappets by the oi l
pump causi ng them to become soft and al l ow val ves
to seat noi si l y.
OIL LEVEL TOO LOW
Low oi l l evel may al l ow pump to take i n ai r whi ch
when fed to the tappets, causes them to become soft
and al l ows val ves to seat noi si l y. Any l eaks on i ntake
si de of pump through whi ch ai r can be drawn wi l l
create the same tappet acti on. Check the l ubri cati on
system from the i ntake strai ner to the pump cover,
i ncl udi ng the rel i ef val ve retai ner cap. When tappet
noi se i s due to aerati on, i t may be i ntermi ttent or
constant, and usual l y more than one tappet wi l l be
noi sy. When oi l l evel and l eaks have been corrected,
engi ne shoul d be operated at fast i dl e to al l ow al l of
the ai r i nsi de of the tappets to be bl ed out.
VALVE TRAIN NOISE DIAGNOSIS
To determi ne source of val ve trai n noi se, operate
engi ne at i dl e wi th cyl i nder head covers removed and
l i sten for source of the noi se.
Fig. 3 3.3/3.8L V-6 Engines
Fig. 4 Roller Tappets Aligning Yoke and Retainer
NS 3. 3/3. 8L ENGINE 9 - 95
NOTE: Worn valve guides or cocked springs are
sometimes mistaken for noisy tappets. If such is
the case, noise may be dampened by applying side
thrust on the valve spring. If noise is not apprecia-
bly reduced, it can be assumed the noise is in the
tappet. Inspect the rocker arm push rod sockets
and push rod ends for wear.
Val ve tappet noi se ranges from l i ght noi se to a
heavy cl i ck. A l i ght noi se i s usual l y caused by exces-
si ve l eak-down around the uni t pl unger whi ch wi l l
necessi tate repl aci ng the tappet, or by the pl unger
parti al l y sti cki ng i n the tappet body cyl i nder. A heavy
cl i ck i s caused ei ther by a tappet check val ve not
seati ng, or by forei gn parti cl es becomi ng wedged
between the pl unger and the tappet body causi ng the
pl unger to sti ck i n the down posi ti on. Thi s heavy
cl i ck wi l l be accompani ed by excessi ve cl earance
between the val ve stem and rocker arm as val ve
cl oses. I n ei ther case, tappet assembl y shoul d be
removed for i nspecti on and cl eani ng.
Check oi l pressure usi ng gauge at oi l pressure
swi tch l ocati on. Oi l pressure shoul d be 34.47 kPa (5
psi .) at i dl e or 205 to 551 kPa (30 to 80 psi .) at 3000
RPM.
(1) Remove pressure sendi ng uni t and i nstal l oi l
pressure gauge (Fi g. 5).
CAUTION: If oil pressure is 0 at idle, do not run
engine at 3000 RPM.
(2) Warm engi ne at hi gh i dl e unti l thermostat
opens.
SERVICE PROCEDURES
VALVE TIMING
(1) Remove front cyl i nder head cover and al l 6
spark pl ugs.
(2) Rotate engi ne unti l the #2 pi ston i s at TDC of
the compressi on stroke.
(3) I nstal l a degree wheel on the crankshaft pul l ey.
(4) Wi th proper adaptor, i nstal l a di al i ndi cator
i nto #2 spark pl ug hol e. Usi ng the i ndi cator fi nd TDC
on the compressi on stroke.
(5) Posi ti on the degree wheel to zero.
(6) Remove di al i ndi cator from spark pl ug hol e.
(7) Pl ace a 5.08 mm (0.200 i n.) spacer between the
val ve stem ti p of #2 i ntake val ve and rocker arm pad.
Al l ow tappet to bl eed down to gi ve a sol i d tappet
effect.
(8) I nstal l a di al i ndi cator so pl unger contacts the
#2 i ntake val ve spri ng retai ner as nearl y perpendi c-
ul ar as possi bl e. Zero the i ndi cator.
(9) Rotate the engi ne cl ockwi se unti l the i ntake
val ve has l i fted .254 mm (0.010 i n.).
CAUTION: Do not turn crankshaft any further
clockwise as intake valve might bottom and result
in serious damage.
(10) Degree wheel shoul d read 6 degrees BTDC to
6 degrees ATDC.
MEASURING TIMING CHAIN FOR STRETCH
(1) Pl ace a scal e next to ti mi ng chai n so that any
movement of chai n may be measured.
(2) Pl ace a torque wrench and socket on camshaft
sprocket attachi ng bol t and appl y torque i n di recti on
of crankshaft rotati on to take up sl ack; 41 Nm (30 ft.
l b.) wi th cyl i nder head i nstal l ed or 20 Nm (15 ft. l b.)
wi th cyl i nder heads removed. With a torque
applied to the camshaft sprocket bolt, crank-
shaft should not be permitted to move. It may
be necessary to block crankshaft to prevent
rotation.
(3) Hol di ng a scal e even, wi th di mensi on readi ng
as shown (Fi g. 6), al ong edge of chai n l i nks. Appl y
torque i n the reverse di recti on to 41 Nm (30 ft. l bs.)
wi th cyl i nder heads i nstal l ed, or 20 Nm (15 ft. l bs.)
wi th cyl i nder heads removed. Check amount of chai n
movement.
(4) I nstal l a new ti mi ng chai n, i f i ts movement
exceeds 3.175 mm (1/8 i nch).
(5) I f chai n i s not sati sfactory, refer to Ti mi ng
Chai n Removal and I nstal l ati on i n thi s secti on. Fig. 5 Checking Oil Pump Pressure
9 - 96 3. 3/3. 8L ENGINE NS
FITTING PISTONS AND RINGS
FITTING PISTONS
The pi ston and cyl i nder wal l must be cl ean and
dry. Pi ston di ameter shoul d be measured 90 degrees
to pi ston pi n at si ze l ocati on shown i n (Fi g. 8). Cyl -
i nder bores shoul d be measured hal fway down the
cyl i nder bore and transverse to the engi ne crankshaft
center l i ne shown i n (Fi g. 7). Refer to Cyl i nder Bore
and Pi ston Speci fi cati on Chart. Pistons and cylin-
der bores should be measured at normal room
temperature, 70F (21C).
FITTING RINGS
(2) Check pi ston ri ng to groove cl earance: (Fi g. 10).
Fi t al l rods on one bank unti l compl ete.
The beari ng caps are not i nterchangeabl e and
shoul d be marked at removal to i nsure correct
assembl y.
The beari ng shel l s must be i nstal l ed wi th the
tangs i nserted i nto the machi ned grooves i n the rods
and caps. I nstal l cap wi th the tangs on the same si de
as the rod.
Li mi ts of taper or out-of-round on any crankshaft
journal s shoul d be hel d to 0.025 mm (0.001 i n.).
Beari ngs are avai l abl e i n 0.025 mm (0.001 i n.) and
0.250 mm (0.010 i n.) undersi ze. Install the bear-
ings in pairs. Do not use a new bearing half
Fig. 6 Measuring Timing Chain Wear and Stretch
SPECIFICATION CHART
Engine
Standard
Bore
Maximum
Out-Of-
Round
Maximum
Taper
3.3L 92.993 -
93.007 mm
0.076 mm 0.51 mm
(3.661 -
3.6617 in.)
(0.003 in.) (0.002 in.)
3.8L 95.993 -
96.007 mm
Same Same
3.7792 -
3.780 in.
3.3L 92.950 - 92.968 mm (3.6594 - 3.6602 in.)
3.8L 95.950 - 95.968 mm (3.7776 - 3.7783 in.)
Piston to Bore Clearance: 0.025 - 0.057 mm
(0.0009 - 0.0022 in.)
Fig. 8 Piston Measurements
NS 3. 3/3. 8L ENGINE 9 - 97
with an old bearing half. Do not file the rods or
bearing caps.
(1) Fol l ow procedure speci fi ed i n the Standard Ser-
vi ce Procedure Secti on for Measuri ng Mai n Beari ng
Cl earance and Connecti ng Rod Beari ng Cl earance
(Fi g. 11).
NOTE: The rod bearing bolts should be examined
before reuse. If the threads are necked down the
bolts should be replaced (Fig. 13). Necking can be
checked by holding a scale or straight edge against
the threads. If all the threads do not contact the
scale the bolt should be replaced.
(2) Before i nstal l i ng the nuts the threads shoul d
be oi l ed wi th engi ne oi l .
(3) I nstal l nuts fi nger ti ght on each bol t then al ter-
natel y torque each nut to assembl e the cap properl y.
(4) Ti ghten the nuts to 54 Nm PLUS 1/4 turn (40
ft. l bs. PLUS 1/4 turn).
(5) Usi ng a feel er gauge, check connecti ng rod si de
cl earance (Fi g. 12). Refer to Connecti ng Rod Speci fi -
cati on Chart.
FITTING MAIN BEARINGS
CRANKSHAFT OIL CLEARANCE
Measure the journal outsi de di ameter as shown i n
(Fi g. 14). Refer to Crankshaft Speci fi cati on Chart.
Ring Position Ring Gap Wear Limit Groove Clearance Maximum Clearance
(0.012 - 0.022 in.)
1.0 mm (0.039 in.) 0.030 - 0.085 mm
(0.001 - 0.003 in.)
0.10 mm (0.004 in.)
(0.012 - 0.022 in.)
1.0 mm (0.039 in.) 0.030 - 0.095 mm
(0.001 - 0.0037 in.)
0.10 mm (0.004 in.)
(0.010 - 0.039 in.)
1.88 mm (0.074 in.) 0.014 - 0.266 mm
(0.0005 - 0.009 in.)
0.266 mm (0.009 in.)
Fig. 9 Check Gap on Piston Rings
Fig. 10 Measuring Piston Ring Side Clearance
Fig. 11 Checking Connecting Rod Bearing
Clearance
9 - 98 3. 3/3. 8L ENGINE NS
PLASTIGAGE (OIL CLEARANCE)
MEASUREMENT
(1) Remove oi l from journal and beari ng shel l .
(2) I nstal l crankshaft.
(3) Cut pl asti gage to same l ength as wi dth of the
beari ng and pl ace i t i n paral l el wi th the journal axi s
(Fi g. 15).
(4) I nstal l the mai n beari ng cap careful l y and
ti ghten the bol ts to speci fi ed torque.
CAUTION: Do not rotate crankshaft or the plasti-
gage will be smeared.
(5) Careful l y remove the beari ng cap and measure
the wi dth of the pl asti gage at the wi dest part usi ng
the scal e on the pl asti gage package (Fi g. 15). Refer to
Crankshaft Speci fi cati on Chart for proper cl earances.
I f the cl earance exceeds the speci fi ed l i mi ts, repl ace
the mai n beari ng(s) and i f necessary, have the crank-
shaft machi ned to next undersi ze.
CRANKSHAFT END PLAY
DIAL INDICATOR METHOD
Connecting Rod Bearing Clearance
New Part: 0.019 - 0.073 mm
(0.0008 - 0.0029 in.)
Wear Limit: 0.074 mm
(0.003 in.)
New Part: 0.13 - 0.32 mm
(0.005 - 0.013 in.)
Wear Limit: 0.38 mm
(0.015 in.)
Fig. 13 Check for Stretched (Necked) Bolts
Crankshaft End-Play
New Part: 0.09 - 0.24 mm
(0.0036 - 0.0095 in.)
Wear Limit: 0.38 mm
(0.015 in.)
Main Bearing Clearance
New Part: 0.011 - 0.059 mm
(0.0005 - 0.0024 in.)
Wear Limit: 0.076 mm
(0.003 in.)
Standard Size: 63.992 - 64.013 mm
(2.5194 - 2.5202 in.)
Standard Size: 57.989 - 58.005 mm
(2.2831 - 2.2837 in.)
NS 3. 3/3. 8L ENGINE 9 - 99
travel .
cati on Chart.
FEELER GAUGE METHOD
cap and a crankshaft cheek usi ng care not to damage
any beari ng surface. Do not l oosen mai n beari ng
cap.
(2) Use a feel er gauge between number 2 thrust
beari ng and machi ned crankshaft surface to deter-
mi ne end pl ay. Refer to Crankshaft Speci fi cati on
Chart.
VALVE INSPECTION
(2) Measure val ve stems for wear. Refer to Val ve
Di mensi on Chart.
CAUTION: Valve stems are chrome plated and
should not be polished.
(4) Measure val ve stem gui de cl earance as fol l ows:
a. I nstal l val ve i nto cyl i nder head so i t i s 14 mm
(0.551 i n.) off the val ve seat. A smal l pi ece of hose
may be used to hol d val ve i n pl ace.
b. Attach di al i ndi cator Tool C-3339 to cyl i nder
head and set i t at ri ght angl e of val ve stem bei ng
measured (Fi g. 17).
(5) Move val ve to and from the i ndi cator. Refer to
Val ve Gui de Speci fi cati on Chart.
(6) Ream the gui des for val ves wi th oversi zed
stems i f di al i ndi cator readi ng i s excessi ve or i f the
stems are scuffed or scored.
(7) Servi ce val ves wi th oversi ze stems and over
si ze seal s are avai l abl e i n 0.15 mm (0.005 i n.), 0.40
mm, (0.015 i n.) and 0.80 mm (0.030 i n.) oversi ze.
NOTE: Oversize seals must be used with oversize
valves.
(8) Refer to Val ve Gui de Speci fi cati on Chart for
reamer si ze to accommodate the oversi ze val ve
stems.
(9) Sl owl y turn reamer by hand and cl ean gui de
thoroughl y before i nstal l i ng new val ve. Do not
attempt to reamthe valve guides fromstandard
directly to 0.80 mm (0.030 in.) Use step proce-
Fig. 15 Measuring Bearing Clearance with
Plastigage
Fig. 16 Checking Crankshaft End Play
Fig. 17 Measuring Valve Guide Wear
9 - 100 3. 3/3. 8L ENGINE NS
dure of 0.15 mm (0.005 in.), 0.40 mm (0.015 in.)
and 0.80 mm (0.030 in.) so the valve guides may
be reamed true in relation to the valve seat.
After reaming guides, the seat runout should be
measured and resurfaced if necessary. See
Refacing Valves and Valve Seats.
VALVE GUIDES
NOTE: Replace cylinder head if guide does not
clean up with 0.80 mm (0.030 in.) oversize reamer,
or if guide is loose in cylinder head.
The i ntake and exhaust val ves have a 44-1/2 to 45
degree face angl e. The val ve seats have a 45 to 45-1/2
degree face angl e. The val ve face and val ve seat
angl es are shown i n (Fi g. 19).
VALVES
are refaced Refer to Val ve Di mensi on Chart.
VALVE SEATS
CAUTION: Remove metal from valve seat only. Do
not remove metal from cylinder head (Fig. 20).
obtai ned.
(2) Measure the concentri ci ty of val ve seat usi ng
di al i ndi cator. Total runout shoul d not exceed 0.051
mm (0.002 i n.) total i ndi cator readi ng.
(3) I nspect the val ve seat usi ng Prussi an bl ue to
ferred to top edge of val ve face, l ower val ve seat wi th
a 15 degree stone. I f the bl ue i s transferred to the
bottom edge of val ve face rai se val ve seat wi th a 65
degrees stone.
Fig. 18 Intake and Exhaust Valves
Intake Valve Exhaust Valve
Dial Indicator
Reading
(Maximum):
0.247 mm
(0.009 in.)
0.414 mm
(0.016 in.)
Valve Guide
Reamer
Oversize
Valve Guide Size
0.15 mm
(0.005 in.)
8.125 - 8.150 mm
(0.3198 - 0.3208 in.)
0.40 mm
(0.015 in.)
8.375 - 8.400 mm
(0.3297 - 0.3307 in.)
0.80 mm
(0.030 in.)
8.775 - 8.800 mm
(0.3454 - 0.3464 in.)
Intake Valve (Minimum)
Face Angle: 44.5
Head Diameter: 45.5 mm (1.79 in.)
Length: 127.2 mm (5.008 in.)
Exhaust Valve (Minimum)
Face Angle: 44.5
Head Diameter: 37.5 mm (1.476 in.)
Length: 127.82 (5.032 in.)
Fig. 19 Valve Seats
NS 3. 3/3. 8L ENGINE 9 - 101
NOTE: Valve seats which are worn or burned can
be reworked, provided that correct angle and seat
width are maintained. Otherwise cylinder head must
be replaced.
i ntake seats shoul d be 1.75 to 2.25 mm (0.69 to 0.088
i n.) The wi dth of the exhaust seats shoul d be 1.50 to
2.00 mm (0.059 to 0.078 i n.) (Fi g. 19).
(5) Check the val ve spri ng i nstal l ed hei ght after
refaci ng the val ve and seat (Fi g. 22).
Whenever val ves have been removed for i nspecti on,
recondi ti oni ng or repl acement, val ve spri ngs shoul d
be tested (Fi g. 21). As an example; the compressi on
l ength of the spri ng to be tested i s 33.34 mm (1-5/16
i nches). Turn tabl e of Tool C-647 unti l surface i s i n
l i ne wi th the 33.34 mm (1-5/16 i nch) mark on the
threaded stud and the zero mark on the front. Pl ace
spri ng over stud on the tabl e and l i ft compressi ng
l ever to set tone devi ce. Pul l on torque wrench unti l
pi ng i s heard. Take readi ng on torque wrench at thi s
i nstant. Mul ti pl y thi s readi ng by two. Thi s wi l l gi ve
the spri ng l oad at test l ength. Fracti onal measure-
ments are i ndi cated on the tabl e for fi ner adjust-
ments. Refer to speci fi cati ons to obtai n speci fi ed
hei ght and al l owabl e tensi ons. Di scard the spri ngs
that do not meet speci fi cati ons.
WIPER UNIT
When performing work on the upper engine.
Refer to Section 8K, Windshield Wipers and
Washers for removal of the Wiper Unit.
ENGINE MOUNTS
RIGHT SIDE MOUNT
REMOVAL
concerns.
harness from engi ne mount.
verti cal fasteners and l oosen the hori zontal fastener,
Do Not remove the l arge nut on the end of the core
from frame rai l (Fi g. 23).
Fig. 20 Refacing Valve Seats
Fig. 21 Testing Valve Springs
Fig. 22 Checking Valve Installed Height
ITEM DESCRIPTION
A Valve Stem Height
B Valve Installed Height
9 - 102 3. 3/3. 8L ENGINE NS
from the engi ne si de bracket. Remove the engi ne
mount assembl y
INSTALLATION
a. Engi ne mount to rai l fasteners to 68 Nm (50 ft.
l bs.).
b. The verti cal engi ne fastener to 102 Nm (75 ft.
l bs.)
c. The hori zontal fastener to 150 Nm (111 ft. l bs.).
(2) I nstal l the purge duty sol enoi d and wi ri ng har-
ness to the engi ne mount.
FRONT MOUNT
REMOVAL
bracket (Fi g. 24).
sary (Fi g. 24).
INSTALLATION
ti ghten fasteners i n thi s order:
a. Ti ghten bol ts 2,3, and 4 to 108 Nm (80 ft. l bs.).
b. Ti ghten bol ts 1 and 5 to 54 Nm (40 ft. l bs.).
Nm (105 i n. l bs.).
LEFT SIDE MOUNT
REMOVAL
wheel .
jack.
mount.
(4) Remove the transmi ssi on mount fasteners and
remove mount.
INSTALLATION
(2) Ti ghten mount to transmi ssi on bol ts to 55 Nm
(40 ft. l bs.)
(3) Ti ghten through bol t to 75 Nm (55 ft. l bs.)
(Fi g. 25).
REAR MOUNT
REMOVAL
jack so i t wi l l not rotate.
(4) Remove the four transmi ssi on mount fasteners
and remove the mount.
INSTALLATION
Refer to (Fi g. 26). Ti ghten through bol t to 75 Nm (55
ft. l bs.)
Fig. 23 Engine MountRight
Fig. 24 Engine MountingFront
NS 3. 3/3. 8L ENGINE 9 - 103
ENGINE MOUNT RUBBER INSULATORS
I nsul ator l ocati on on (ri ght si de) i s adjustabl e to
al l ow ri ght/l eft dri ve trai n adjustment i n rel ati on to
dri ve shaft assembl y l ength.
Check and reposi ti on ri ght engi ne mount i nsul ator.
See Adjustments i n thi s secti on. Adjust dri ve trai n
posi ti on, i f requi red, for the fol l owi ng condi ti ons:
a. Dri ve shaft di stress. See Group 2, Suspensi on
and Dri veshafts.
b. Any front end structural damage (after repai r).
c. I nsul ator repl acement.
ENGINE ASSEMBLY
REMOVAL
to group 14 fuel system for procedure. Remove fuel
(3) Remove ai r cl eaner and hoses.
(4) Remove battery cover, battery and battery tray,
wi th i ntegral vacuum reservoi r, from vehi cl e.
(5) Bl ock off heater hoses to rear heater assembl y,
i f equi pped.
(8) Remove fan modul e and radi ator. Refer to
Group 7 Cool i ng System for procedure.
(10) Di sconnect throttl e body l i nkage and vacuum
hoses from throttl e body.
(11) Remove accessory dri ve bel ts. Refer to Group
7, Accessory Dri ve Bel ts l ocated i n Cool i ng System
for procedure.
(12) Remove ai r condi ti oni ng compressor from
engi ne and set i t asi de.
(13) Di sconnect generator wi ri ng harness and
remove generator.
(14) Hoi st vehi cl e and remove ri ght and l eft i nner
spl ash shi el ds.
(15) Remove crossmember cradl e pl ate (Fi g. 27).
(16) Remove axl e shafts. Refer to Group 3, Di ffer-
enti al and Dri vel i ne for procedure.
(17) (AWD equipped) Mark ori entati on and sepa-
rate propel l er shaft from power transfer uni t. Refer
to Group 3, Di fferenti al and Dri vel i ne for procedure.
(19) Remove front engi ne mount and bracket as an
assembl y.
Fig. 25 Engine MountingLeft
Fig. 26 Engine MountingRear
Fig. 27 Crossmember Cradle Plate
9 - 104 3. 3/3. 8L ENGINE NS
(20) Remove rear transmi ssi on mount and bracket.
(21) Remove power steeri ng pump and bracket
assembl y.
(22) Remove wi ri ng harness and connectors from
front of engi ne.
(23) Remove bendi ng braces and i nstal l tool num-
ber 6912 on engi ne.
(24) Remove transmi ssi on i nspecti on cover and
mark fl expl ate to torque converter.
(25) Remove dri vepl ate to torque converter bol ts.
Speci al Tool 6135 and cradl e Speci al Tool 6710 wi th
post Speci al Tool 6848 and adaptor Speci al Tool 6909
to be i nstal l ed under vehi cl e (Fi g. 28).
(29) Loosen cradl e engi ne mounts to al l ow move-
ment for posi ti oni ng onto engi ne l ocati ng hol es on the
engi ne. Lower vehi cl e and posi ti on cradl e mounts
transmi ssi on.
ENGINE AND TRANSMISSION i s on the cradl e.
(31) Remove ri ght engi ne mount assembl y and l eft
transmi ssi on mount through bol t. Refer to Engi ne
Mounts Secti on of thi s Group.
to al l ow for removal around body fl anges.
INSTALLATION
engi ne and transmi ssi on. I t may be necessary to
move the engi ne/transmi ssi on assembl y wi th the cra-
dl e for cl earance around body fl anges.
engi ne dol l y and cradl e Speci al Tool s 6135, 6710,
6848 and 6909.
(4) Remove Speci al tool s 6912 and i nstal l bendi ng
braces.
(5) Lower vehi cl e. I nstal l generator and wi ri ng
harness.
(6) Connect wi ri ng harness on the front of the
engi ne.
(7) I nstal l Ai r Condi ti oni ng Compressor.
(8) I nstal l power steeri ng pump and bracket and
accessory dri ve bel t. Refer to Accessory dri ve Secti on
Located i n group 7 for i nstal l ati on procedure.
(9) Rai se vehi cl e and i nstal l axl e shafts. Refer to
Group 3, Di fferenti al and Dri vel i ne for procedure.
(10) I nstal l transmi ssi on and engi ne mount and
bracket assembl i es. Refer to Engi ne Mounts secti on
of thi s Group.
(11) (AWD equipped) I nstal l propel l er shaft to
power transfer uni t. Refer to Group 3, Di fferenti al
and Dri vel i ne for procedure.
(13) I nstal l crossmember cradl e pl ate (Fi g. 27).
(14) I nstal l l eft and ri ght i nner spl ash shi el ds.
(15) Connect automati c transmi ssi on shi fter l i nk-
age. Refer to Group 21, Transmi ssi on for procedures.
(16) Lower vehi cl e and connect fuel l i ne and
heater hoses. Remove pl ugs from rear heater hoses
and i nstal l , i f equi pped.
throttl e body connecti ons and harnesses.
(19) I nstal l radi ator and fan modul e assembl y.
I nstal l radi ator hoses. Fi l l cool i ng system. See Group
7 for fi l l i ng procedure.
(20) I nstal l battery tray, battery and cover.
ature i s reached.
Fig. 28 Positioning Engine Cradle Support Post
MountsTypical
NS 3. 3/3. 8L ENGINE 9 - 105
CRANKSHAFT DAMPER
REMOVAL
(3) Remove ri ght wheel and i nner spl ash shi el d.
(4) Remove dri ve bel t. Refer to Group 7, Cool i ng
(5) Remove crankshaft pul l ey (Fi g. 29).
INSTALLATION
(1) I nstal l crankshaft pul l ey (Fi g. 30).
(2) I nstal l dri ve bel t. Refer to Cool i ng System
Group 7 for i nstal l ati on procedure.
(3) I nstal l i nner spl ash shi el d and wheel .
ROCKER ARMS AND SHAFT ASSEMBLY
REMOVAL
(1) Remove upper i ntake mani fol d assembl y. Refer
to Group 11, I ntake and Exhaust Mani fol ds.
(2) Di sconnect spark pl ug wi res by pul l i ng on the
boot strai ght out i n l i ne wi th pl ug.
(3) Di sconnect cl osed venti l ati on system.
(4) Remove cyl i nder head cover and gasket.
(5) Remove four rocker shaft bol ts and retai ners.
(6) Remove rocker arms and shaft assembl y.
(7) I f rocker arm assembl i es are di sassembl ed for
cl eani ng or repl acement. Assembl e rocker arms i n
thei r ori gi nal posi ti on. Refer to (Fi g. 31) for rocker
arm for posi ti oni ng on the shaft.
INSTALLATION
(1) I nstal l rocker arm and shaft assembl i es wi th
the stamped steel retai ners i n the four posi ti ons,
ti ghten to 28 Nm (250 i n. l bs.) (Fi g. 31).
CAUTION: THE ROCKER ARM SHAFT SHOULD BE
TORQUED DOWN SLOWLY, STARTING WITH THE
CENTER BOLTS. ALLOW 20 MINUTES TAPPET
BLEED DOWN TIME AFTER INSTALLATION OF THE
ROCKER SHAFTS BEFORE ENGINE OPERATION.
(2) Cl ean cyl i nder head cover gasket surface.
I nspect cover for di storti on and strai ghten i f neces-
sary.
(3) Cl ean head rai l i f necessary. I nstal l a new gas-
ket and ti ghten cyl i nder head cover fasteners to 12
Nm (105 i n. l bs.).
(4) I nstal l cl osed crankcase venti l ati on system.
(5) I nstal l spark pl ug wi res.
(6) I nstal l upper i ntake mani fol d assembl y. Refer
to Group 11, Exhaust Systems and I ntake Mani fol ds.
VALVE STEM SEALS OR SPRINGS, CYLINDER
HEAD NOT REMOVED
(1) Perform fuel system pressure rel ease procedure
before attempting any repairs.
(3) Remove ai r cl eaner cover and hose assembl y.
Fig. 31 Rocker Arm Location Left Bank
9 - 106 3. 3/3. 8L ENGINE NS
(4) Remove upper i ntake mani fol d. Refer to Group
11, Exhaust System and I ntake Mani fol ds for proce-
dure.
(5) Remove cyl i nder head covers and spark pl ugs.
(6) Remove el ectri cal connector from i gni ti on coi l s.
(7) Usi ng sui tabl e socket and fl ex handl e at crank-
shaft pul l ey retai ni ng screw, turn engi ne so the num-
ber 1 pi ston i s at Top Dead Center on the
compressi on stroke.
(8) Remove rocker arms wi th rocker shaft and
i nstal l a dummy shaft. The rocker arms shoul d not
be di sturbed and l eft on shaft.
(9) Wi th ai r hose attached to spark pl ug adapter
i nstal l ed i n number 1 spark pl ug hol e, appl y 90 to
100 psi ai r pressure (620.5 to 689 kPa). Thi s i s to
hol d val ves i n pl ace whi l e servi ci ng components.
(10) Usi ng Tool C-4682 or equi val ent, compress
val ve spri ng and remove retai ner val ve l ocks and
val ve spri ng.
(11) The i ntake val ve stem seal s shoul d be pushed
fi rml y and squarel y over the val ve gui de usi ng the
val ve stem as gui de. Do Not Force seal agai nst top
of gui de. When i nstal l i ng the val ve retai ner l ocks,
compress the spri ng only enough to i nstal l the
l ocks.
CAUTION: Do not pinch seal between retainer and
top of valve guide.
(12) Fol l ow the same procedure on the remai ni ng 5
cyl i nders usi ng the fi ri ng sequence 1-2-3-4-5-6. Make
sure piston in cylinder is at TDC on the valve
spring that is being covered.
(13) Remove spark pl ug adapter tool .
(14) Remove dummy shaft and i nstal l rocker shaft
assembl y and ti ghten screws to 28 Nm (250 i n. l bs.).
(15) I nstal l cyl i nder head covers ti ghten screws to
14 Nm (120 i n. l bs.) and el ectri cal connector to i gni -
ti on coi l s.
(16) I nstal l I ntake Mani fol d. Refer to Group 11,
Exhaust System and I ntake Mani fol d for procedure.
CYLINDER HEAD COVER
REMOVAL
NOTE: The cylinder head cover can be either an
isolated type (Fig. 32) or a non-isolated type.
FRONT CYLINDER HEAD COVER
(1) Di sconnect i gni ti on cabl es from spark pl ugs.
(2) Di sconnect crankcase vent hose from cyl i nder
head cover.
(3) Remove front cyl i nder head cover bol ts.
REAR CYLINDER HEAD COVER
(2) Remove Wi per Uni t. Refer to Group 8K, Wi nd-
shi el d Wi pers and Washers for procedure.
(3) Remove i ntake mani fol d upper pl enum. Refer
to Group 11, Exhaust System and I ntake Mani fol d
for procedure.
(4) Di sconnect PCV hose from cyl i nder head cover.
(5) Remove rear cyl i nder head cover bol ts
INSTALLATION
FRONT CYLINDER HEAD COVER
I nspect cyl i nder head cover surface for fl atness.
Repl ace gasket as necessary.
(2) I nstal l cyl i nder head cover and bol ts.
(3) Ti ghten cyl i nder head cover bol ts to the fol l ow-
i ng speci fi cati ons:
Nonisolated cyl i nder head cover to 12 Nm
(105 i n. l bs.).
Isolated cyl i nder head cover to 10 Nm (90 i n.
l bs.) (Fi g. 32).
(4) Connect crankcase vent hose.
(5) Connect i gni ti on cabl es to spark pl ugs.
REAR CYLINDER HEAD COVER
I nspect cyl i nder head cover surface for fl atness.
Repl ace gasket as necessary.
(2) I nstal l cyl i nder head cover and bol ts.
(3) Ti ghten cyl i nder head cover bol ts to the fol l ow-
i ng speci fi cati ons:
Fig. 32 Cylinder Head CoverIsolated Type
NS 3. 3/3. 8L ENGINE 9 - 107
Nonisolated cyl i nder head cover to 12 Nm
(105 i n. l bs.).
Isolated cyl i nder head cover to 10 Nm (90 i n.
l bs.) (Fi g. 32).
(4) Connect PCV hose from cyl i nder head cover.
(5) I nstal l i ntake mani fol d upper pl enum. Refer to
procedure.
(6) I nstal l Wi per Uni t. Refer to Group 8K, Wi nd-
shi el d Wi pers and Washers for procedure.
CYLINDER HEAD
REMOVAL
System for procedure and di sconnect negati ve cabl e
from battery.
(2) Remove upper and l ower i ntake mani fol ds.
Refer to Group 11, Exhaust System and I ntake Man-
i fol d.
WARNING: INTAKE MANIFOLD GASKET IS MADE
OF VERY THIN METAL AND MAY CAUSE PER-
SONAL INJURY, HANDLE WITH CARE.
(3) Di sconnect coi l wi res, sendi ng uni t wi re, heater
hoses and bypass hose.
(4) Remove PCV system hoses, evaporati on control
system hose and cyl i nder head covers.
(5) Remove exhaust mani fol ds.
(6) Remove rocker arm and shaft assembl i es.
Remove push rods and mark positions to ensure
installation in original locations.
(7) Remove the 9 head bol ts from each cyl i nder
head and remove cyl i nder heads (Fi g. 33).
INSTALLATION
(1) Cl ean al l seal i ng surfaces of cyl i nder bl ock and
cyl i nder heads.
(2) I nstal l new gaskets on cyl i nder bl ock (Fi g. 34).
(3) The cylinder head bolts are torqued using
the torque yield method, they should be exam-
ined BEFORE reuse. If the threads are necked
down, the bolts should be replaced (Fi g. 35).
(4) Necki ng can be checked by hol di ng a scal e or
strai ght edge agai nst the threads. I f al l the threads
do not contact the scal e the bol t shoul d be repl aced.
(5) Ti ghten the cyl i nder head bol ts 1 - 8 i n the
sequence shown i n (Fi g. 33). Usi ng the 4 step torque
turn method, ti ghten accordi ng to the fol l owi ng val -
ues:
Step 1: Bol ts 1 8 to 61 Nm (45 ft. l bs.)
Step 2: Bol ts 1 8 to 88 Nm (65 ft. l bs.)
Step 3: Bol ts 1 8 (agai n) to 88 Nm (65 ft. l bs.)
Step 4: Bol ts 1 8 turn an addi ti onal 1/4 Turn.
(Do not use a torque wrench for this step.)
NOTE: Bolt torque after 1/4 turn should be over 122
Nm (90 ft. lbs.). If not, replace the bolt.
(6) Ti ghten head bol t number 9 (Fi g. 33) to 33 Nm
(25 ft. l bs.) after head bol ts 1 8 have been ti ghten
to speci fi cati ons.
Fig. 33 Cylinder Head Bolts Location and
Tightening Sequence
Fig. 34 Head Gasket Installation
Fig. 35 Checking Bolts for Stretching (Necking)
9 - 108 3. 3/3. 8L ENGINE NS
(7) I nspect push rods and repl ace worn or bent
rods.
(8) I nstal l push rods, rocker arm and shaft assem-
bl i es wi th the stamped steel retai ners i n the four
posi ti ons, ti ghten to 28 Nm (250 i n. l bs.) (Fi g. 36).
(9) Pl ace new cyl i nder head cover gaskets i n posi -
ti on and i nstal l cyl i nder head covers. Ti ghten to 12
Nm (105 i n. l bs.).
INTAKE MANIFOLD SEALING
The i ntake mani fol d gasket i s a one-pi ece stamped
steel gasket wi th a seal er appl i ed from the manufac-
turer. Thi s gasket has end seal s i ncorporated wi th i t.
(1) Cl ean al l surfaces of cyl i nder bl ock and cyl i n-
der heads.
(2) Pl ace a drop (about 1/4 i n. di ameter) of Mopar
Si l i cone Rubber Adhesi ve Seal ant or equi val ent, onto
each of the four mani fol d to cyl i nder head gasket
corners (Fi g. 37).
(3) Careful l y i nstal l the i ntake mani fol d gasket
(Fi g. 38). Torque end seal retai ner screws to 12 Nm
(105 i n. l bs.).
(4) I nstal l i ntake mani fol d and (8) bol ts and torque
to 1 Nm (10 i n. l bs.). Then ti ghten bol ts to 22 Nm
(200 i n. l bs.) i n sequence shown i n (Fi g. 39). Then
ti ghten agai n to 22 Nm (200 i n. l bs.). After i ntake
mani fol d i s i n pl ace, inspect to make sure seals
are in place. Refer to Group 11, Exhaust System
and I ntake Mani fol d to compl ete i ntake mani fol d
i nstal l ati on.
(5) I nstal l exhaust mani fol ds and ti ghten bol ts to
27 Nm (20 ft. l bs.) and nuts to 20 Nm (15 ft. l bs.).
(6) Adjust spark pl ugs to speci fi cati on i n Group 8,
El ectri cal Secti on and i nstal l the pl ugs.
REMOVAL
spri ngs usi ng Val ve Spri ng Compressor Tool
C-3422-B wi th adapter 6412 as shown i n (Fi g. 40).
Fig. 36 Rocker Arm Shaft Retainers
Fig. 37 Intake Manifold Gasket Sealing
Fig. 38 Intake Manifold Gasket Retainers
Fig. 39 Intake Manifold Removal and Installation
NS 3. 3/3. 8L ENGINE 9 - 109
VALVE INSTALLATION
i nsert them i n cyl i nder head.
(2) Check val ve ti p to spri ng seat di mensi ons A
after gri ndi ng the val ve seats or faces. Gri nd val ve
ti p to gi ve 49.541 to 51.271 mm (1.950 to 2.018 i n.)
over spri ng seat when i nstal l ed i n the head (Fi g. 41).
Check val ve ti p for scori ng, i f necessary, the ti p
chamfer shoul d be reground to prevent seal damage
when the val ve i s i nstal l ed.
(3) I nstal l val ve spri ng seat spacer on head (Fi g.
42).
(4) I nstal l new cup seal s on al l val ve stems and
over val ve gui des (Fi g. 41). I nstal l val ve spri ngs and
val ve retai ners (Fi g. 42).
(5) Compress val ve spri ngs wi th Val ve Spri ng
Compressor Tool C-3422-B, wi th adapter 6412 i nstal l
l ocks and rel ease tool . If valves and/or seats are
reground, measure the installed height of
springs dimension B, make sure measurements
are taken from top of spring seat to the bottom
surface of spring retainer. If height is greater
than 1-19/32 inches, (40.6 mm), install a 1/32
inch (.794 mm) spacer in head counterbore to
bring spring height back to normal 1-17/32 to
1-19/32 inch (39.1 to 40.6 mm).
TAPPET REMOVAL
(1) Refer to Cyl i nder Head Removal i n thi s secti on.
Cyl i nder Head must be removed to gai n access to
tappets for servi ce.
(2) Remove yoke retai ner and al i gni ng yokes.
(3) Use Tool C-4129 to remove tappets from thei r
bores. I f al l tappets are to be removed, i denti fy tap-
pets to i nsure i nstal l ati on i n ori gi nal l ocati on.
NOTE: If the tappet or bore in cylinder block is
scored, scuffed, or shows signs of sticking, ream
the bore to next oversize and replace with oversize
tappet.
CAUTION: The plunger and tappet bodies are not
interchangeable. The plunger and valve must
always be fitted to the original body. It is advisable
to work on one tappet at a time to avoid mixing of
parts. Mixed parts are not compatible. Do not disas-
semble a tappet on a dirty work bench.
INSTALLATION
(1) Lubri cate tappets.
(2) I nstal l tappets i n thei r ori gi nal posi ti ons.
(3) Wi th rol l er tappets, i nstal l al i gni ng yokes (Fi g.
43).
(4) I nstal l yoke retai ner and torque screws to 12
Nm (105 i n. l bs.) (Fi g. 43).
(5) I nstal l cyl i nder heads. Refer to cyl i nder head
i nstal l ati on of thi s secti on for procedure.
Fig. 40 Compress Valve Springs with Special Tool
C-3422-B with Adapter 6412
Fig. 41 Checking Valve Installed Height
Fig. 42 Valve Seal and SpringInstallation
9 - 110 3. 3/3. 8L ENGINE NS
(6) Start and operate engi ne. Warm up to normal
CAUTION: To prevent damage to valve mechanism,
engine must not be run above fast idle until all
hydraulic tappets have filled with oil and have
become quiet.
TIMING CHAIN COVER
REMOVAL
(2) Drai n cool i ng system. Refer to Cool i ng System
Group 7 for procedure.
(3) Support engi ne and remove ri ght engi ne
mount.
(4) Rai se vehi cl e on hoi st. Drai n engi ne oi l .
(5) Remove oi l pan and oi l pump pi ck-up. I t may
necessary to remove transaxl e i nspecti on cover.
(6) Remove ri ght wheel and i nner spl ash shi el d.
(7) Remove dri ve bel t. Refer to Cool i ng System
(8) Remove A/C compressor and set asi de.
(9) Remove A/C compressor mounti ng bracket.
(10) Remove crankshaft damper (Fi g. 44).
(11) Remove i dl er pul l ey from engi ne bracket.
(12) Remove engi ne bracket (Fi g. 45).
(13) Remove cam sensor from chai n case cover
(Fi g. 46).
(14) Remove chai n case cover (Fi g. 46).
INSTALLATION
(1) Be sure mati ng surfaces of chai n case cover
and cyl i nder bl ock are cl ean and free from burrs.
Crankshaft oi l seal must be removed to i nsure cor-
rect oi l pump engagement.
NOTE: DO NOT USE SEALER ON COVER GASKET
(2) Use a new cover gasket, and O-ri ngs (Fi g. 47).
Adhere new gasket to chai n case cover, maki ng sure
that the l ower edge of the gasket i s fl ush to 0.5 mm
(0.020 i n.) passed the l ower edge of the cover. Refer
to Oi l Pan seal i ng outl i ned i n thi s secti on.
Fig. 43 Roller Tappets Aligning Yoke and Retainer
Fig. 45 Engine Bracket
Fig. 46 Timing Chain Case Cover
NS 3. 3/3. 8L ENGINE 9 - 111
(3) Rotate crankshaft so that the oi l pump dri ve
fl ats are verti cal .
(4) Posi ti on oi l pump i nner rotor so the mati ng
fl ats are i n the same posi ti on as the crankshaft dri ve
fl ats (Fi g. 47).
(5) I nstal l cover onto crankshaft. Make sure the oi l
pump i s engaged on the crankshaft correctl y or
severe damage may resul t.
(6) I nstal l chai n case cover screws and torque to
27 Nm (20 ft. l bs.).
(7) I nstal l crankshaft oi l seal (Fi g. 48).
(8) I nstal l crankshaft pul l ey (Fi g. 49).
(9) I nstal l engi ne bracket (Fi g. 45) and torque fas-
teners to 54 Nm (40 ft. l bs.).
(10) I nstal l i dl er pul l ey on engi ne bracket.
(11) I nstal l cam sensor. Refer to Group 8D, I gni -
ti on System for i nstal l ati on procedure.
(12) I nstal l A/C compressor mounti ng bracket.
(13) I nstal l A/C compressor.
(14) I nstal l dri ve bel t Refer to Group 7, Cool i ng
System for i nstal l ati on procedure.
(16) I nstal l oi l pump pi ck-up and oi l pan and tran-
saxl e i nspecti on cover i f removed.
(17) I nstal l engi ne mount.
(18) Fi l l crankcase wi th oi l to proper l evel .
TIMING CHAIN
REMOVAL
(2) Remove ti mi ng chai n cover. Refer to procedure
(3) Remove camshaft sprocket attachi ng bol t, and
ti mi ng chai n wi th camshaft sprocket.
(4) Usi ng a sui tabl e pul l er remove the crankshaft
sprocket. Be careful not to damage the crankshaft
surface.
INSTALLATION
(1) Posi ti on a new crankshaft sprocket on the
shaft, i nstal l sprocket wi th sui tabl e tool and mal l et.
Be sure sprocket i s seated i nto posi ti on.
(2) Rotate crankshaft so the ti mi ng arrow i s to the
12 ocl ock posi ti on.
(3) Pl ace ti mi ng chai n around camshaft sprocket
and pl ace the ti mi ng mark to the 6 ocl ock posi ti on.
(4) Al i gn the dark col ored l i nks wi th the dot on the
camshaft sprocket, pl ace ti mi ng chai n around crank-
shaft sprocket wi th the dark col ored l i nk l i ned up
Fig. 47 Timing Chain Case Cover Gaskets and
O-Rings
Fig. 48 Crankshaft Oil SealInstallation
9 - 112 3. 3/3. 8L ENGINE NS
wi th the dot on the sprocket and i nstal l camshaft
sprocket i nto posi ti on.
(5) Use a strai ght edge to check al i gnment of ti m-
i ng marks (Fi g. 50).
(6) I nstal l camshaft bol t and washer. Ti ghten to 54
Nm (40 ft. l bs.).
(7) Rotate crankshaft 2 revol uti ons. Ti mi ng marks
shoul d l i ne up. I f ti mi ng marks do not l i ne up
remove cam sprocket and real i gn.
(8) Check camshaft end pl ay. Wi th new thrust
pl ate the speci fi cati on i s 0.0127 to 0.304 mm (0.005
to 0.012 i n.). Ol d thrust pl ate speci fi cati on i s 0.31
mm (0.012 i n.) maxi mum. I f not wi thi n these l i mi ts
i nstal l new thrust pl ate.
(9) I nstal l ti mi ng chai n cover and connect negati ve
cabl e to battery.
CAMSHAFT
REMOVALENGINE REMOVED FROM
VEHICLE
Remove i ntake mani fol d, cyl i nder head covers, cyl -
i nder heads, ti mi ng chai n case cover and ti mi ng
chai n.
(1) Remove rocker arm and shaft assembl i es.
(2) Remove push rods and tappets; i denti fy so each
part wi l l be repl aced i n i ts ori gi nal l ocati on.
(3) Remove camshaft thrust pl ate (Fi g. 51).
(4) I nstal l a l ong bol t i nto front of camshaft to
faci l i tate removal of the camshaft; remove camshaft,
bei ng careful not to damage cam beari ngs wi th the
cam l obes.
INSTALLATION
(1) Lubri cate camshaft l obes and camshaft beari ng
journal s and i nsert the camshaft to wi thi n 2 i nches
of i ts fi nal posi ti on i n cyl i nder bl ock.
(2) I nstal l camshaft thrust pl ate wi th two screws
as shown i n (Fi g. 51). Ti ghten to 12 Nm (105 i n. l bs.)
torque.
(3) Rotate crankshaft so the ti mi ng arrow i s at the
12 ocl ock posi ti on.
(4) Pl ace ti mi ng chai n around camshaft sprocket
and pl ace the ti mi ng mark to the 6 ocl ock posi ti on.
(5) Al i gn the dark col ored l i nks wi th the dot on the
camshaft sprocket, pl ace ti mi ng chai n around crank-
shaft sprocket wi th the dark col ored l i nk l i ned up
wi th the dot on the sprocket and i nstal l camshaft
sprocket i nto posi ti on.
(6) Usi ng strai ght edge to check al i gnment of ti m-
i ng marks (Fi g. 52).
(7) I nstal l the camshaft bol t. Ti ghten bol t to 54
Nm (40 ft. l bs.).
(8) Rotate crankshaft 2 revol uti ons. Ti mi ng marks
shoul d l i ne up. I f ti mi ng marks do not l i ne up,
remove cam sprocket and real i gn.
(9) Measure camshaft end pl ay. End Pl ay shoul d
measure 0.0127 to 0.304 mm (0.005 to 0.012 i nches.)
Fig. 50 Timing Marks Alignment
Fig. 51 Camshaft Thrust Plate
Fig. 52 Alignment of Timing Marks
NS 3. 3/3. 8L ENGINE 9 - 113
0.310 mm (0.012 i n. Max.). I f not wi thi n l i mi ts i nstal l
a new thrust pl ate.
(10) Each tappet reused must be i nstal l ed i n the
same posi ti on from whi ch i t was removed. When
camshaft is replaced, all of the tappets must be
replaced.
CAMSHAFT BEARINGS
REMOVAL
(1) Wi th engi ne removed from vehi cl e and com-
pl etel y di sassembl ed, dri ve out rear cam beari ng core
hol e pl ug.
(2) I nstal l proper si ze adapters and horseshoe
washers (part of Tool C-3132-A) at back of each bear-
i ng shel l to be removed and dri ve out beari ng shel l s
(Fi g. 53).
INSTALLATION
(1) I nstal l new camshaft beari ngs wi th Tool
C-3132-A by sl i di ng the new camshaft beari ng shel l
over proper adapter.
(2) Posi ti on rear beari ng i n the tool . I nstal l horse-
shoe l ock and by reversi ng removal procedure, care-
ful l y dri ve beari ng shel l i nto pl ace.
(3) I nstal l remai ni ng beari ngs i n the same man-
ner. Beari ngs must be careful l y al i gned to bri ng oi l
hol es i nto ful l regi ster wi th oi l passages from the
mai n beari ng. Number two beari ng must i ndex wi th
the oi l passage to the l eft cyl i nder head and Number
three beari ng must i ndex wi th the oi l passage to the
ri ght cyl i nder head. I f the camshaft beari ng shel l oi l
hol es are not i n exact al i gnment, remove and rei n-
stal l them correctl y. I nstal l a new core hol e pl ug at
the rear of camshaft. Be sure this plug does not
leak.
OIL PAN
REMOVAL
(1) Di sconnect negati ve cabl e from battery and
remove engi ne oi l di psti ck.
(2) Rai se vehi cl e on hoi st and drai n engi ne oi l .
(3) Remove bendi ng brace to transaxl e attachi ng
bol t.
(4) Remove bol ts attachi ng dust cover to transaxl e
housi ng. Lower dust cover to gai n access to oi l pan
bol ts.
(5) Remove oi l pan screws and remove oi l pan.
INSTALLATION
(1) Cl ean surfaces and appl y a 1/8 i nch bead of
Mopar Si l i cone Rubber Adhesi ve Seal ant or equi va-
l ent, at the parti ng l i ne of the chai n case cover and
the rear seal retai ner (Fi g. 54).
(2) Use a new pan gasket (Fi g. 55).
(3) I nstal l pan and ti ghten screws to 12 Nm (105
i n. l b.).
(4) I nstal l dust shi el d and bendi ng brace to tran-
saxl e housi ng.
(5) Lower vehi cl e and i nstal l oi l di psti ck.
(7) Fi l l crankcase wi th oi l to proper l evel .
Fig. 53 Removed Installation of Camshaft Bearings
with Tool C-3132ATypical
Fig. 55 Oil Pan Gasket Installation
9 - 114 3. 3/3. 8L ENGINE NS
REMOVAL
(2) Remove cyl i nder heads and oi l pan. Refer to
procedure outl i ned i n thi s secti on.
covered during this operation. Pistons and con-
necting rods must be removed from top of cyl-
inder block. When removing piston and
connecting rod assemblies from the engine,
rotate crankshaft so that each connecting rod
is centered in cylinder bore.
(4) I nspect connecti ng rods and connecti ng rod
caps for cyl i nder i denti fi cati on. I denti fy them i f nec-
essary (Fi g. 56).
(5) Remove connecti ng rod cap. I nstal l connecti ng
rod bol t protectors on connecti ng rod bol ts (Fi g. 57).
Push each pi ston and rod assembl y out of cyl i nder
bore.
i ng rod.
INSTALLING PISTON AND CONNECTING ROD
ASSEMBLY
oi l ri ng rai l gap (Fi g. 58).
rai l gaps l ocated as shown i n (Fi g. 58).
(3) Lubri cate the pi ston and ri ngs wi th cl ean
engi ne oi l . Posi ti on a ri ng compressor over the pi ston
and ri ngs, and ti ghten the compressor. Be sure posi-
tion of rings does not change during this oper-
ation.
(4) I nstal l connecti ng rod bol t protectors on rod
bol ts (Fi g. 57).
rod and pi ston i nto cyl i nder bore and gui de rod over
the crankshaft journal .
Fig. 57 Connecting Rod Protectors
Fig. 59 PistonInstallation
NS 3. 3/3. 8L ENGINE 9 - 115
(7) The notch or groove on top of pi ston must be
poi nti ng toward front of engi ne (Fi g. 60).
(8) I nstal l rod caps. I nstal l nuts on cl eaned and
oi l ed rod bol ts and ti ghten nuts to 54 Nm (40 ft. l b.)
Pl us 1/4 turn.
(9) Repeat procedure for each pi ston and rod
i nstal l ati on.
(10) I nstal l cyl i nder heads and oi l pan.
(11) Fi l l engi ne crankcase wi th proper oi l to cor-
rect l evel .
CRANKSHAFT
MAIN BEARINGS
Beari ng caps are not i nterchangeabl e and shoul d
be marked at removal to i nsure correct assembl y
(Fi g. 62). Upper and l ower beari ng hal ves are NOT
i nterchangeabl e. Lower mai n beari ng hal ves of 1, 3
and 4 are i nterchangeabl e. Upper mai n beari ng
hal ves of 1, 3 and 4 are i nterchangeabl e.
CRANKSHAFT MAIN J OURNALS
excessi ve wear, taper and scori ng. (Fi g. 61) Li mi ts of
taper or out-of-round on any crankshaft journal s
shoul d be hel d to 0.025 mm (0.001 i n.). Journal
gri ndi ng shoul d not exceed 0.305 mm (0.012 i n.)
under the standard journal di ameter. Do NOT gri nd
thrust faces of Number 2 mai n beari ng. Do NOT ni ck
crank pi n or beari ng fi l l ets. After gri ndi ng, remove
rough edges from crankshaft oi l hol es and cl ean out
al l passages.
standard and the fol l owi ng undersi zes: 0.025 mm
(0.001 i n.) and 0.254 mm (0.010 i n). Never i nstal l an
undersi ze beari ng that wi l l reduce cl earance bel ow
speci fi cati ons.
REMOVAL
(1) Remove oi l pan and i denti fy beari ng caps
before removal .
(2) Remove beari ng caps one at a ti me. Remove
upper hal f of beari ng by i nserti ng Speci al Mai n Bear-
i ng Tool C-3059. (Fi g. 64) i nto the oi l hol e of crank-
shaft.
Fig. 60 Piston I.D. Notches
Fig. 62 Main Bearing Cap Identification
9 - 116 3. 3/3. 8L ENGINE NS
(3) Sl owl y rotate crankshaft cl ockwi se, forci ng out
upper hal f of beari ng shel l .
INSTALLATION
NOTE: Only one main bearing should be selec-
tively fitted while all other main bearing caps are
properly tightened.
When i nstal l i ng a new upper beari ng shel l , sl i ghtl y
chamfer the sharp edges from the pl ai n si de.
(1) Start beari ng i n pl ace, and i nsert Mai n Beari ng
Tool C-3059 i nto oi l hol e of crankshaft (Fi g. 64).
(2) Sl owl y rotate crankshaft countercl ockwi se sl i d-
i ng the beari ng i nto posi ti on. Remove Speci al Mai n
Beari ng Tool C-3059.
(3) I nstal l each mai n cap and ti ghten bol ts fi nger
ti ght.
(4) Ti ghten number 1, 3 and 4 mai n cap bol ts to 41
Nm + 1/4 Turn (30 ft. l bs.+ 1/4 Turn).
(5) Rotate the crankshaft unti l number 6 pi ston i s
at TDC.
(6) To ensure correct thrust beari ng al i gnment the
fol l owi ng procedure must be done:
a. Move crankshaft al l the way to the rear of i ts
travel .
b. Then, move crankshaft al l the way to the front
of i ts travel .
c. Wedge a appropri ate tool between the rear of
the cyl i nder bl ock and rear crankshaft counter-
wei ght. Thi s wi l l hol d the crankshaft i n i ts most for-
ward posi ti on.
d. Ti ghten the #2 Thrust Beari ng cap bol ts to 41
Nm + 1/4 Turn (30 ft. l bs.+ 1/4 Turn). Remove the
hol di ng tool .
(7) I nstal l oi l pan.
(8) Fi l l engi ne crankcase wi th proper oi l to correct
l evel .
CRANKSHAFT OIL SEAL FRONT
REMOVAL
(2) Rai se vehi cl e on hoi st. Remove ri ght wheel and
i nner spl ash shi el d.
(3) Remove dri ve bel t. Refer to Group 7, Cool i ng
(4) Remove crankshaft damper (Fi g. 65).
(5) Usi ng Tool 6341A to remove oi l seal (Fi g. 66).
Be careful not to damage that crankshaft seal sur-
face of cover.
INSTALLATION
(1) I nstal l new seal by usi ng Tool C-4992 (Fi g. 67).
wi th cover.
(3) I nstal l crankshaft pul l ey usi ng pl ate L-4524.
Thrust Beari ng/washer and 5.9 i nch screw (Fi g. 68).
Fig. 63 Main Bearing Identification
Fig. 64 Removing and Installing Upper Main Bearing
With Special Tool C-3059
NS 3. 3/3. 8L ENGINE 9 - 117
(4) I nstal l dri ve bel t Refer to Group 7, Cool i ng
System for i nstal l ati on procedure.
(6) Lower vehi cl e and connect negati ve cabl e to
battery.
CRANKSHAFT OIL SEAL REAR
REMOVAL
(1) I nsert a 3/16 fl at bl aded pry tool between the
dust l i p and the metal case of the crankshaft seal .
Angl e the pry tool (Fi g. 69) through the dust l i p
agai nst metal case of the seal . Pry out seal .
CAUTION: Do not permit the pry tool blade to con-
tact crankshaft seal surface. Contact of the pry tool
blade against crankshaft edge (chamfer) is permit-
ted.
INSTALLATION
tion of new seal.
(1) Pl ace Speci al Tool 6926-1 magneti c pi l ot tool on
crankshaft (Fi g. 70).
(2) Li ghtl y coat seal O.D. wi th Mopar Stud N
Beari ng Mount Adhesi ve or equi val ent.
(3) Pl ace seal over Speci al Tool 6926-1 Pi l ot. Usi ng
Speci al Tool 6926-2 I nstal l er wi th C-4171 Handl e,
dri ve seal i nto the retai ner housi ng (Fi g. 70).
REAR CRANKSHAFT SEAL RETAINER
When retai ner removal i s requi red, remove
retai ner and cl ean engi ne bl ock and retai ner of ol d
gasket. Make sure surfaces are cl ean and free of oi l .
Fig. 67 Crankshaft Oil SealInstallation
9 - 118 3. 3/3. 8L ENGINE NS
I nstal l new gasket and ti ghten screws to 12 Nm (105
i n. l bs.).
OIL FILTER
CAUTION: When servicing the oil filter (Fig. 71)
avoid deforming the filter can by installing the
remove/install tool band strap against the can-to-
base lock seam. The lock seam joining the can to
the base is reinforced by the base plate.
(1) Usi ng Tool C-4065, turn fi l ter countercl ockwi se
to remove from base. Properl y di scard fi l ter.
(2) Wi pe base cl ean, then i nspect gasket contact
surface.
(3) Lubri cate gasket of new fi l ter wi th cl ean
engi ne oi l .
(4) I nstal l new fi l ter unti l gasket contacts base.
Ti ghten fi l ter 1 turn or 20 Nm (15 ft. l bs.). Use fi l ter
wrench i f necessary.
(5) Start engi ne and check for l eaks.
ENGINE OIL GALLERY PLUGS
REMOVAL
Usi ng a bl unt tool such as a dri ft and a hammer,
stri ke the bottom edge of the cup pl ug. Wi th the cup
pl ug rotated, grasp fi rml y wi th pl i ers or other sui t-
abl e tool and remove pl ug (Fi g. 72).
CAUTION: Do not drive cup plug into the casting
as restricted cooling can result and cause serious
engine problems.
INSTALLATION
Thoroughl y cl ean i nsi de of cup pl ug hol e i n cyl i n-
der bl ock or head. Be sure to remove ol d seal er.
Li ghtl y coat i nsi de of cup pl ug hol e wi th Locti te Stud
N Beari ng Mount or equi val ent. Make certai n the
new pl ug i s cl eaned of al l oi l or grease. Usi ng proper
dri ve pl ug, dri ve pl ug i nto hol e so that the sharp
edge of the pl ug i s at l east 0.5 mm (0.020 i n.) i nsi de
the l ead-i n chamfer.
OIL PUMP
I t i s necessary to remove the oi l pan, oi l pi ckup
and chai n case cover to servi ce the oi l pump rotors.
The oi l pump pressure rel i ef val ve can be servi ced by
removi ng the oi l pan and oi l pi ckup tube. Refer to
Ti mi ng Chai n Cover Removal and I nstal l ati on of thi s
secti on for procedures.
DISASSEMBLY
Fig. 70 Rear Crankshaft Oil SealInstallation
Fig. 71 Oil Filter
Fig. 72 Core Hole Plug Removal
NS 3. 3/3. 8L ENGINE 9 - 119
(2) Dri l l a 3.175 mm (1/8 i nch) hol e i nto the rel i ef
val ve retai ner cap and i nsert a sel f-threadi ng sheet
metal screw i nto cap.
(3) Cl amp screw i nto a vi se and whi l e supporti ng
chai n case cover, remove cap by tappi ng chai n case
cover usi ng a soft hammer. Di scard retai ner cap and
remove spri ng and rel i ef val ve (Fi g. 73).
cover.
(6) Wash al l parts i n a sui tabl e sol vent and i nspect
careful l y for damage or wear (Fi g. 76).
OIL PUMP ASSEMBLY
(1) Assembl e pump, usi ng new parts as requi red.
Install the inner rotor with chamfer facing the
cast iron oil pump cover.
(2) Ti ghten cover screws to 12 Nm (105 i n. l bs.).
(3) Pri me oi l pump before i nstal l ati on by fi l l i ng
rotor cavi ty wi th engi ne oi l .
(4) I nstal l chai n case cover. Refer to Ti mi ng Chai n
Cover I nstal l ati on of thi s secti on.
HYDRAULIC TAPPETS
DISASSEMBLY
(1) Pry out pl unger retai ner spri ng cl i p (Fi g. 74).
(2) Cl ean varni sh deposi ts from i nsi de of tappet
body above pl unger cap.
(3) I nvert tappet body and remove pl unger cap,
pl unger, fl at or bal l check val ve, check val ve spri ng,
check val ve retai ner and pl unger spri ng. Check val ve
coul d be fl at or bal l .
ASSEMBLY
(1) Cl ean al l tappet parts i n a sol vent that wi l l
remove al l varni sh and carbon.
(2) Repl ace tappets that are unfi t for further ser-
vi ce wi th new assembl i es.
(3) I f pl unger shows si gns of scori ng or wear, val ve
i s pi tted, or val ve seat on end of pl unger i ndi cates
any condi ti on that woul d prevent val ve from seati ng,
i nstal l a new tappet assembl y.
(4) Assembl e tappets (Fi g. 74).
CYLINDER HEAD
(1) Before cl eani ng, check for l eaks, damage and
cracks.
(2) Cl ean cyl i nder head and oi l passages.
(3) Check cyl i nder head for fl atness (Fi g. 75).
(4) I nspect al l surfaces wi th a strai ghtedge i f there
i s any reason to suspect l eakage. I f out of fl atness
exceeds 0.019 mm (0.00075 i n.) ti mes the span l ength
i n i nches, i n any di recti on, ei ther repl ace head or
l i ghtl y machi ne the head surface. As an exampl e, i f a
12 i nch span i s 0.1 mm (.004 i n.) out of fl at, al l ow-
abl e i s 12 x .019 mm (.00075 i n.) equal s .22 mm (.009
i n.) Thi s amount of out of fl at i s acceptabl e. Maxi -
mum of 0.2 mm (.008 i n.) for gri ndi ng i s permi tted.
CAUTION: This is a combined total dimension of
stock removal from cylinder head and block top
surface.
Fig. 74 Hydraulic Roller Tappet Assembly
Fig. 75 Check Cylinder Head
9 - 120 3. 3/3. 8L ENGINE NS
OIL PAN
(1) Cl ean oi l pan i n sol vent and wi pe dry wi th a
cl ean cl oth. Cl ean al l gasket materi al from mounti ng
surfaces of pan and bl ock.
(2) I nspect oi l drai n pl ug and pl ug hol e for
stri pped or damaged threads and repai r as necessary.
I nstal l a new drai n pl ug gasket. Ti ghten to 27 Nm
(20 ft. l bs.).
(3) I nspect oi l pan mounti ng fl ange for bends or
di storti on. Strai ghten fl ange i f necessary.
(4) Cl ean oi l screen and pi pe i n cl ean sol vent.
I nspect condi ti on of screen.
OIL PUMP
INSPECTION AND REPAIR
the chai n case cover shoul d be smooth. Repl ace pump
cover i f scratched or grooved.
face (Fi g. 77). I f a 0.025 mm (0.001 i n.) feel er gauge
can be i nserted between cover and strai ght edge,
cover shoul d be repl aced.
I f outer rotor thi ckness measures 7.64 mm (0.301 i n.)
or l ess (Fi g. 78), or i f the di ameter i s 79.95 mm
(3.148 i nches.) or l ess, repl ace outer rotor.
(4) I f i nner rotor measures 7.64 mm (0.301 i n.) or
(5) Sl i de outer rotor i nto chai n case cover, press to
rotor and chai n case cover (Fi g. 80). I f measurement
i s 0.39 mm (0.015 i n.) or more, repl ace CCC onl y i f
outer rotor i s i n speci fi cati on.
(6) I nstal l i nner rotor i nto chai n case cover. I f
cl earance between i nner and outer rotors (Fi g. 81) i s
0.203 mm (0.008 i n.) or more, repl ace both rotors.
chai n case cover, between bol t hol es. I f a feel er gauge
of 0.10 mm (0.004 i n.) or more can be i nserted
assembl y (Fi g. 82). ONLY i f rotors are i n specs.
may be removed wi th 400-gri t wet or dry sandpaper.
between 19.5 and 20.5 pounds when compressed to
34 mm (1-11/32 i nches). Repl ace spri ng that fai l s to
meet speci fi cati ons (Fi g. 73).
(10) I f oi l pressure i s l ow and pump i s wi thi n spec-
i fi cati ons, i nspect for worn engi ne beari ngs or other
reasons for oi l pressure l oss.
ENGINE BLOCK AND BORE
Fig. 76 Oil Pump
NS 3. 3/3. 8L ENGINE 9 - 121
(2) I f new core pl ugs are i nstal l ed, see Engi ne Core
Oi l and Cam Pl ugs.
(3) Exami ne bl ock for cracks or fractures.
round and taper wi th Tool C-119 (Fi g. 83). I f the cyl -
i nder wal l s are badl y scuffed or scored, the cyl i nder
bl ock shoul d be repl aced.
12 mm (0.50 i n.) down and bottom measurement
shoul d be 12 mm (0.50 i n.) up from bottom of bore.
Chart.
Housing
9 - 122 3. 3/3. 8L ENGINE NS
ADJ USTMENTS
ENGINE MOUNTS
screws.
suri ng.
fol l owi ng order:
150 Nm (110 ft. l bs.).
ft. l bs.).
SPECIFICATIONS
3. 3/3. 8L ENGINE
Type. . . . . . . . . . . . . . . . . . . . . . . . .60 V-6 Engi ne
Bore3.3L . . . . . . . . . . . . . . . . . .93.0 mm (3.66 i n.)
Bore3.8L . . . . . . . . . . . . . . . . .96.0 mm (3.779 i n.)
Stroke3.3L . . . . . . . . . . . . . . .81.0 mm (3.188 i n.)
Stroke3.8L . . . . . . . . . . . . . . .87.0 mm (3.425 i n.)
Compressi on Rati o3.3L . . . . . . . . . . . . . . . . .8.9:1
Compressi on Rati o3.8L . . . . . . . . . . . . . . . . .9.6:1
Di spl acement3.3L. . . . . . . . . .3.3L (201 Cubi c i n.)
Di spl acement3.8L. . . . . . . . . .3.8L (231 Cubi c i n.)
Brake Horsepower3.3L . . . . . . . .158 @ 4850 RPM
Brake Horsepower3.8L . . . . . . . .180 @ 4400 RPM
Torque3.3L . . . . . . . . . . . .203 l b. ft. @ 3600 RPM
Torque3.8L . . . . . . . . . . . .240 l b. ft. @ 3600 RPM
Fi ri ng Order . . . . . . . . . . . . . . . . . . . .123456
Compressi on Pressure.Refer to Engi ne Performance
i n Standard Servi ce Procedures.
Cylinder Number (Front to Rear)
Front Bank . . . . . . . . . . . . . . . . . . . . . . . . . . .2,4,6
Rear Bank . . . . . . . . . . . . . . . . . . . . . . . . . . . .1,3,6
Cylinder Block
Cyl i nder Bore (Standard)3.3L . . . . . . . . .93.0 mm
(3.66 i n.)
Cyl i nder Bore (Standard)3.8L . . . . . . . . .96.0 mm
(3.779 i n.)
Taper (Max.). . . . . . . . . . . . . .0.051 mm (0.002 i n.)
Cyl i nder Bore Oversi ze (Max.). . . . . . . . .0.508 mm
(0.020 i n.)
Tappet Bore Di ameter . . . . .22.9896 - 23.0099 mm
(0.9051 - 0.9059 i n.)
Pistons
Type Materi al . . . . . . .Al umi num Al l oy Ti n Coated
Cl earance at Si ze Locati on. . . . . .0.025 - 0.057 mm
(0.001 - 0.0022 i n.)
Wei ght (Standard Onl y)3.3L . . . . . .381 5 grams
(13.4394 0.1764 oz.)
Wei ght (Standard Onl y)3.8L . . . . . .438 5 grams
(15.4501 0.1764 oz.)
Pi stons for Servi ce . . . . . . . . . . . . . .Standard Onl y
Piston Pins
Type . . . . . . . . . . . . . . . . . . . . . . .Press Fi t i n Rod
(Servi ced as an Assembl y)
Di ameter . . . . . . . . . . . . . . . . . . . . . . . . .22.88 mm
(0.9009 - 0.9007 i n.)
Length3.3L . . . . . . . . . . . . . . . .67.25 - 67.75 mm
(2.648 - 2.667 i n.)
Lenth3.8L . . . . . . . . . . . . . . . . .71.25 - 71.75 mm
(2.805 - 2.824 i n.)
Cl earance i n Pi ston @ 70 . . . . . .0.006 - 0.019 mm
(0.0002 - 0.0007 i n.)
Cl earance i n Rod . . . . . . . . . . . . . . . .(I nterference)
SPECIFICATION CHART
Engine
Standard
Bore
Maximum
Out-Of-
Round
Maximum
Taper
3.3L 92.993 -
93.007 mm
0.076 mm 0.51 mm
(3.661 -
3.6617 in.)
(0.003 in.) (0.002 in.)
3.8L 95.993 -
96.007 mm
Same Same
3.7792 -
3.780 in.
3.3L 92.950 - 92.968 mm
(3.6594 - 3.6602 in.)
3.8L 95.950 - 95.968 mm
(3.7776 - 3.7783 in.)
Piston to Bore Clearance: 0.025 - 0.057 mm
(0.0009 - 0.0022 in.)
NS 3. 3/3. 8L ENGINE 9 - 123
Piston Rings
Number of Ri ngs . . . . . . . . . . . . . . . . . . . . . . . . . .3
Compressi on . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Oi l Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Oi l Ri ng Type . . .3Pi ece, Steel Rai l , Chrome Face
Piston Ring Gap
Top & 2nd Compressi on i ng. . . . . . .0.30 - 0.55 mm
(0.0118 - 0.0217 i n.)
Oi l Control (Steel Rai l s) . . . . . . . . .0.25 - 1.00 mm
(0.0098 - 0.0394 i n.)
Service Rings
Ri ng GapCompressi on . . . . . . . .0.300 - 0.550 mm
(0.0118 - 0.0217 i n.)
Ri ng GapOi l Control . . . . . . . . . .0.250 - 1.00 mm
(0.0098 - 0.0394 i n.)
Piston Ring Side Clearance
Top & 2nd Compressi on Ri ngs . . .0.030 - 0.095 mm
(0.0012 - 0.0037 i n.)
Oi l Ri ng (Steel Rai l s). . . . . . . . . .0.014 - 0.226 mm
(0.0005 - 0.0089 i n.)
Piston Ring Width
Compressi on Ri ngs . . . . . . . . . . . . .1.46 - 1.50 mm
(0.0575 - 0.0591 i n.)
Oi l Ri ng (Steel Rai l s). . . . . . . . . . . . . . . .0.510 mm
(0.0201 i n.)
Connecting Rods
Beari ng Type . . . . . . . . .Al umi num Lead (Bi metal )
(0.00075 - 0.0026 i n.)
Max. Al l owabl e . . . . . . . . . .0.076 mm (0.003 i n.)
Si de Cl earance . . . . . . . . . . . . . .0.127 - 0.381 mm
(0.005 - 0.015 i n.)
Crankshaft
Type . . . . . . . . . . . . . . . . . . . . . .Cast Nodul ar I ron
Beari ng Type . . . . . . . . .Al umi num Lead (Bi metal )
Thrust Locati on. . . . . . . . . . . . . . . . .No. 2 Beari ng
Connecti ng Rod
(2.124 - 2.125 i n.)
Mai n Beari ng Di ametri cal
Cl earance No. 1- 4. . . . . . . . . . . .0.011 - 0.059 mm
(0.0043 - 0.0023 i n.)
End Pl ay . . . . .0.09 - 0.24 mm (0.0036 - 0.0095 i n.)
Di ameter . . . . . . . . . . . . . . . . .64.013 - 63.993 mm
(2.5202 - 2.5195 i n.)
Taper (Max.). . . . . . . . . . . . . .0.025 mm (0.001 i n.)
Connecting Rod J ournals
Di ameter . . . . . . . . . . . . . . . . .58.005 - 57.979 mm
(2.2837 - 2.2827 i n.)
Taper (Max.). . . . . . . . . . . . . .0.025 mm (0.001 i n.)
Camshaft
Dri ve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Chai n
Beari ngs. . . . . . . . . . . . . . . . .Steel Backed Babbi tt
Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Di ametri cal Cl earance . . . . . . . . .0.025 - 0.101 mm
(0.001 - 0.004 i n.)
Thrust Taken By . . . . . . . . . . . . . . . . .Thrust Pl ate
End Pl ay . . . . . . . . . . . . . . . . . . .0.127 - 0.304 mm
(0.005 - 0.012 i n.)
Camshaft J ournals
Beari ng Journal
Di ameter No. 1 . . . . . . . . . . . .50.724 - 50.775 mm
(1.997 - 1.999 i n.)
Beari ng Journal
Di ameter No. 2 . . . . . . . . . . . .50.317 - 50.368 mm
(1.9809 - 1.9829 i n.)
Beari ng Journal
Di ameter No. 3 . . . . . . . . . . . .49.936 - 49.987 mm
(1.9659 - 1.9679 i n.)
Beari ng Journal
Di ameter No. 4 . . . . . . . . . . . .49.530 - 49.581 mm
(1.9499 - 1.9520 i n.)
Camshaft Bearings
Di ameter No. 1. . . . . . . . . . . . .50.825 - 50.800 mm
(2.0009 - 1.9999 i n.)
Di ameter No. 2. . . . . . . . . . . . .50.419 - 50.393 mm
(1.9849 - 1.9839 i n.)
Di ameter No. 3. . . . . . . . . . . . .50.038 - 50.013 mm
(1.9699 - 1.9690 i n.)
Di ameter No. 4. . . . . . . . . . . . .49.632 - 49.606 mm
(1.954 - 1.9529 i n.)
Oi l Cl earance . . . . . . . . . . . . . .0.0254 - 0.0762 mm
(0.001 - 0.003 i n.)
Valve Timing Exhaust Valve
Cl oses (ATC) . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Opens (BBC) . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Durati on . . . . . . . . . . . . . . . . . . . . . . . . . . . . .240
Valve Timing Intake Valve
Cl oses (BTDC) . . . . . . . . . . . . . . . . . . . . . . . . . .58
Opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Durati on . . . . . . . . . . . . . . . . . . . . . . . . . . . . .240
Val ve Overl ap . . . . . . . . . . . . . . . . . . . . . . . . . .14
Timing Chain
Number of Li nks . . . . . . . . . . . . . . . . . . . . . . . . .64
Pi tch . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.375 i nch
Wi dth . . . . . . . . . . . . . . . . . . . . . . . . . . .0.750 i nch
Hydraulic Tappets
Type . . . . . . . . . . . . . . . . . . . . . . .Rol l er Hydraul i c
Body Di ameter . . . . . . . . . . . . . . .22.95 - 22.96 mm
(0.9035 - 0.9040 i n.)
Cl earance i n Bl ock. . . . . . . . . . . . . .0.02 - 0.06 mm
(0.0007 - 0.0024 i n.)
9 - 124 3. 3/3. 8L ENGINE NS
Servi ce Tappets Avai l abl e . . . . . . . .Std., 0.025 mm
(0.001), 0.20 mm (0.008 i n.),
0.762 mm (0.030 i n.)
Cylinder Head
Gasket Thi ckness (Compressed) . . . . . . . .1.78 mm
(0.070 i n.)
Angl eI ntake and Exhaust . . . . . . . . . . .45 - 45.5
Runout (Max) . . . . . . . . . . . .0.0762 mm (0.003 i n.)
Wi dth (Fi ni sh)I ntake . . . . . . . . . . .1.75 - 2.25 mm
(0.069 - 0.088 i n.)
Wi dth (Fi ni sh)Exhaust . . . . . . . . .1.50 - 2.00 mm
(0.057 - 0.078 i n.)
Valve Guides
Type. . . . . . . . . . . . . . . . . .Powdered Metal I nserts
Gui de Bore Di ameter . . . . . . . . . . .7.975 - 8.00 mm
(0.314 - 0.315 i n.)
ValvesIntake
Face Angl e . . . . . . . . . . . . . . . . . . . . . . . . . . .44.5
Head Di ameter . . . . . . . . . . . . . .45.5 mm (1.79 i n.)
Length (Overal l ). . . . . . . . . .127.005 - 128.036 mm
(5.000 - 5.041 i n.)
Mi ni mum Val ve Length
After Ti p Gri ndi ng . . . . . . . . . . . . . . . . . . .124.892
(4.916 i n.)
Li ft (Zero Lash) . . . . . . . . . . .10.16 mm (0.400 i n.)
Stem Di ameter (Standard). . . . . .7.935 - 7.953 mm
(0.312 - 0.313 i n.)
Val ve Ti p Hei ght (From
Cyl i nder Head Surface) . . . . . .49.541 - 51.271 mm
(1.950 - 2.018 i n.)
Stem-to-Gui de Cl earance . . . . . . .0.025 - 0.095 mm
(0.001 - 0.003 i n.)
Max. Al l owabl e (Rocki ng Method) . . . .0.247 mm
(0.010 i n.)
Val ves for Servi ce
(Oversi ze Stem Di ameters). . . . . . .Std., 0.015 mm
(0.005 i n.), 0.40 mm (0.015 i n.),
0.80 mm (0.030 i n.)
ValvesExhaust
Face Angl e . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Head Di ameter . . . . . . . . . . . . .37.5 mm (1.476 i n.)
Length Overal l . . . . . . . . . . . . . .127.825 - 128.465
(5.032 - 5.058 i n.)
Mi ni mum Val ve Length
After Ti p Gri ndi ng . . . . . . .125.512 mm (4.941 i n.)
Li ft (Zero Lash) . . . . . . . . . . . .10.16 mm (0.40 i n.)
Val ve Ti p Hei ght (From
Cyl i nder Head Surface) . . . . . .49.541 - 51.271 mm
(1.950 - 2.018 i n.)
Stem Di ameter (Standar). . . . . . .7.906 - 7.924 mm
(0.3112 - 0.3119 i n.)
Stem to Gui de Cl earance . . . . . . .0.051 - 0.175 mm
(0.002 - 0.006 i n.)
Max. Al l owabl e (Rocki ng Method) . . . . . .0.414 mm
(0.016 i n.)
Val ves for Servi ce (Oversi ze
Stem Di ameters). . . . . .Std., 0.015 mm (0.005 i n.),
0.40 mm (0.015 i n.), 0.80 mm (0.030 i n.)
Valve Springs
Wi re Di ameter . . . . . . . . . . . . .4.75 mm (0.187 i n.)
Number of Coi l s . . . . . . . . . . . . . . . . . . . . . . . . .6.8
Spri ng Tensi on (Val ve Cl osed) . . . . . . .95 - 100 l bs.
@ 1.57 i n.
Spri ng Tensi on (Val ve Open) . . . . . . .207 - 229 l bs.
@ 1.169 i n.
I nstal l ed Hei ght (Spri ng
Seat to Bottom of Retai ner) . . . . . . 41.2 - 42.7 mm
(1.622 - 1.681 i n.)
Oil Pump
Pump Type . . . . . . . . . . . . . . .Rotary Ful l Pressure
Cl earance Over Rotors
(I nner & Outer Max.). . . . . . . .0.10 mm (0.004 i n.)
I nner Rotor Thi ckness (Mi n.) . .7.64 mm (0.301 i n.)
Outer Rotor Thi ckness (Mi n.). .7.64 mm (0.301 i n.)
Outer Rotor Di ameter (Mi n.) .79.95 mm (3.148 i n.)
Outer Rotor Cl earance . . . . . . .0.39 mm (0.015 i n.)
Ti p Cl earance Between Rotors (Max.) . . . .0.20 mm
(0.008 i n.)
Oil Pressure
Mi ni mum Pressure at I dl e (Engi ne
Ful l y Warmed Up) *. . . . . . . . . . .34.47 kPa (5 psi )
At 3000 rpm . . . . . . . . .205 - 551 kPa (30 - 80 psi )
Oi l Fi l ter Bypass Val ve Setti ng. . . . . .62 - 103 kPa
(9 - 15 psi )
Oi l Fi l ter Type . . . . . . . . . . . . . . . . . . . . .Ful l Fl ow
Oi l Pressure Swi tch Actuati ng
Pressure (Mi n.). . . . . . . . . . .14 - 28 kPa (2 - 4 psi )
NS 3. 3/3. 8L ENGINE 9 - 125
TORQUE CHART
DESCRIPTION TORQUE
A/C Compressor Mounting
Compressor Bracket to Water Pump Bol t . .41 Nm
(30 ft. l bs.)
Compressor to Bracket Bol t. . . .68 Nm (50 ft. l bs.)
Compressor Support Bol t . . . . .41 Nm (30 ft. l bs.)
Camshaft Sprocket
Bol t . . . . . . . . . . . . . . . . . . . . . .54 Nm (40 ft. l bs.)
Camshaft Thrust Plate
Bol t . . . . . . . . . . . . . . . . . . . . .12 Nm (105 i n. l bs.)
Connecting Rod
Nut . . . . . . . . . . . . . . .54 Nm (40 ft. l bs.) +
1
4 Turn
Crankshaft Damper Pulley to Crankshaft
Bol t . . . . . . . . . . . . . . . . . . . . . .54 Nm (40 ft. l bs.)
Cylinder Head
Bol ts . . . . . . .Refer to Cyl i nder Head Removal and
I nstal l ati on Procedure i n thi s Secti on
Cylinder Head Cover
Bol ts . . . . . . . . . . . . . . . . . . . .12 Nm (105 i n. l bs.)
Exhaust Manifold
Bol ts . . . . . . . . . . . . . . . . . . . .23 Nm (200 i n. l bs.)
Exhaust Crossover Pipe Flange
Fasteners. . . . . . . . . . . . . . . . . .33 Nm (25 ft. l bs.)
Generator Mounting
Adjusti ng Strap Bol t . . . . . . . .23 Nm (200 i n. l bs.)
Adjusti ng Strap Mounti ng Bol t . . . . . . . . . .41 Nm
(30 ft. l bs.)
Bracket Bol t . . . . . . . . . . . . . . .41 Nm (30 ft. l bs.)
Pi vot Nut. . . . . . . . . . . . . . . . . .41 Nm (30 ft. l bs.)
Intake Manifold
Bol ts . . . . . . . . . . . . . . . . . . . .23 Nm (200 i n. l bs.)
Intake Manifold Gasket Retaining
Screws . . . . . . . . . . . . . . . . . .12 Nm (105 i n. l bs.)
Intake Manifold Plenum
Bol ts . . . . . . . . . . . . . . . . . . . .28 Nm (250 i n. l bs.)
Main Bearing Cap
Bol ts . . . . . . . . . . . . . .41 Nm (30 ft. l bs.) +
1
4 Turn
Oil Filter Attaching
Ni ppl e . . . . . . . . . . . . . . . . . . . .41 Nm (30 ft. l bs.)
DESCRIPTION TORQUE
Oil Pan
Bol ts . . . . . . . . . . . . . . . . . . . .12 Nm (105 i n. l bs.)
Level Sensor Pl ug . . . . . . . . . . .41 Nm (30 ft. l bs.)
Oil Pressure Gauge Sending Unit
. . . . . . . . . . . . . . . . . . . . . . . . . .7 Nm (60 i n. l bs.)
Oil Pump
Cover Bol ts . . . . . . . . . . . . . . .12 Nm (105 i n. l bs.)
Pi ck-up Tube Bol t . . . . . . . . . .28 Nm (250 i n. l bs.)
Rocker Shaft Bracket
Bol ts . . . . . . . . . . . . . . . . . . . .28 Nm (250 i n. l bs.)
Spark Plug
. . . . . . . . . . . . . . . . . . . . . . . . .27 Nm (20 ft. l bs.)
Starter Mounting
Bol t . . . . . . . . . . . . . . . . . . . . . .68 Nm (50 ft. l bs.)
StrutIntake Manifold to Cylinder Head
Bol t . . . . . . . . . . . . . . . . . . . . . .54 Nm (40 ft. l bs.)
Tappet Retainer Yoke
Bol t . . . . . . . . . . . . . . . . . . . . .12 Nm (105 i n. l bs.)
Temperature Gauge Sending Unit
. . . . . . . . . . . . . . . . . . . . . . . . . .7 Nm (60 i n. l bs.)
Timing Chain Case Cover
Bol tM8 1.25 . . . . . . . . . . . . .27 Nm (20 ft. l bs.)
Bol tM10 1.5 . . . . . . . . . . . . .54 Nm (40 ft. l bs.)
Water Pump to Chain Case Cover
Bol ts . . . . . . . . . . . . . . . . . . . .12 Nm (105 i n. l bs.)
9 - 126 3. 3/3. 8L ENGINE NS
SPECIAL TOOLS
3. 3/3. 8L ENGINE
Adaptor 6909
Dolly 6135
Cradle 6710
Adaptor 6912
Puller 1023
Indicator, Cylinder Bore C-119
NS 3. 3/3. 8L ENGINE 9 - 127
Tester Valve Spring C-647
Valve Spring Compressor C-3422B
Adaptor Valve Compressor 6412
Insert Crankshaft Pulley Remover L-4524-1
Front Crankshaft Seal Installer C-4992
Camshaft Bearing Remover and Installer C-3132A
Crankshaft Main Bearing Remover and Installer
C-3059
6926-2
Oil Filter Wrench C-4065
9 - 128 3. 3/3. 8L ENGINE NS
ENGINE
CONTENTS
page page
2. 0L SOHC ENGINE . . . . . . . . . . . . . . . . . . . . . . 1 2. 5L VM DIESEL . . . . . . . . . . . . . . . . . . . . . . . 40
2.0L SOHC ENGINE
INDEX
page page
GENERAL SPECIFICATION . . . . . . . . . . . . . . . . 2
CHECKING ENGINE OIL PRESSURE . . . . . . . . 3
SERVICE PROCEDURES
CYLINDER BORE AND PISTON SIZING . . . . . . . 4
FITTING CONNECTING RODS . . . . . . . . . . . . . . 5
FITTING CRANKSHAFT BEARINGS . . . . . . . . . . 6
FITTING PISTON RINGS . . . . . . . . . . . . . . . . . . 4
CAMSHAFT OIL SEAL . . . . . . . . . . . . . . . . . . . 12
CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
CRANKSHAFT OIL SEALREAR . . . . . . . . . . . 20
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . 21
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . 10
FRONT CRANKSHAFT OIL SEAL . . . . . . . . . . . 18
OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
OIL FILTER ADAPTER . . . . . . . . . . . . . . . . . . . 24
OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
ROCKER ARM/HYDRAULIC LASH ADJUSTER . . 8
SPARK PLUG TUBE . . . . . . . . . . . . . . . . . . . . . . 7
TIMING BELT COVER . . . . . . . . . . . . . . . . . . . 11
TIMING BELT SYSTEM . . . . . . . . . . . . . . . . . . 13
VALVE SEALS AND SPRINGS IN VEHICLE . . . 10
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
VALVE SERVICE WITH THE CYLINDER HEAD
REMOVED . . . . . . . . . . . . . . . . . . . . . . . . . . 29
CYLINDER BLOCK AND BORE . . . . . . . . . . . . 34
CYLINDER HEAD AND CAMSHAFT
JOURNALS . . . . . . . . . . . . . . . . . . . . . . . . . . 32
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
SPECIFICATIONS
ENGINE 2.0L SOHC . . . . . . . . . . . . . . . . . . . . . 34
TORQUE CHART 2.0L SOHC . . . . . . . . . . . . . . 36
SPECIAL TOOLS
ENGINE 2.0L SOHC . . . . . . . . . . . . . . . . . . . . . 36
l eft rear of the cyl i nder bl ock behi nd starter (Fi g. 1).
Fig. 1 Engine Identification SOHC
NS/GS ENGINE 9 - 1
GENERAL SPECIFICATION
Type . . . . . . . . . . . . . I n-Li ne OHV, DOHC & SOHC
Bore . . . . . . . . . . . . . . . . . . . . . 87.5mm (3.445 I nch)
Stroke . . . . . . . . . . . . . . . . . . . 83.0mm (3.268 i nch)
Compressi on Rati o . . . . DOHC - 9.6:1 SOHC - 9.8:1
Di spl acement . . . . . . . . . 2.0 Li ters (122 Cubi c I nch)
Fi ri ng Order . . . . . . . . . . . . . . . . . . . . . . . . 1, 3, 4, 2
Compressi on Pressure . . . . . . . . . . . 1172 - 1551 kPa
(170 - 225 psi )
Maxi mum Vari ati on Between Cyl i nders . . . . . . 25%
Lubri cati on . . . Pressure Feed - Ful l Fl ow Fi l trati on
(Crankshaft Dri ven Pump)
Engi ne Oi l Capaci ty . . Refer to Group 0, Lubri cati on
and Mai ntenance
ENGINE LUBRICATION
Refer to Group 0, Lubri cati on and Mai ntenance for
recommended oi l to be used i n vari ous engi ne appl i -
cati on. System i s ful l fl ow fi l trati on, pressure feed
type. The oi l pump i s mounted i n the front engi ne
cover and dri ven by the crankshaft. Pressuri zed oi l i s
then routed through the mai n oi l gal l ery, runni ng the
l ength of the cyl i nder bl ock, suppl yi ng mai n and rod
beari ngs wi th further routi ng. Rod beari ng oi l throw-
off l ubri cates the pi stons from di rected sl ots on the
si de of the connecti ng rod assembl i es. Camshaft and
val ve mechani sms are l ubri cated from a ful l -l ength
cyl i nder head oi l gal l ery suppl i ed from the crankcase
mai n oi l gal l ery.
PRESSURE LUBRICATION
Oi l drawn up through the pi ckup tube i s pressur-
i zed by the pump and routed through the ful l fl ow fi l -
ter to the mai n oi l gal l ery runni ng the l ength of the
cyl i nder bl ock. A cyl i nder head restri ctor, l ocated i n
the bl ock, provi des i ncreased oi l fl ow to the mai n oi l
gal l ery (Fi g. 2).
MAIN/ROD BEARINGS
A di agonal hol e i n each bul khead feeds oi l to each
mai n beari ng. Dri l l ed passages wi thi n the crankshaft
route oi l from mai n beari ng journal s to connecti ng
rod journal s.
CAMSHAFT/HYDRAULIC LASH ADJ USTERS
A verti cal hol e at the number fi ve bul khead routes
pressuri zed oi l through a restri ctor up i nto the cyl i n-
der head. The rocker shafts route oi l to the rocker
arms/hydraul i c l ash adjuster assembl i es.
Engine Lubrication Components
9 - 2 ENGINE NS/GS
SPLASH LUBRICATION
Oi l returni ng to the pan from pressuri zed compo-
nents suppl i es l ubri cati on to the val ve stems. Cyl i n-
der bores and wri st pi ns are spl ash l ubri cated from
di rected sl ots on the connecti ng rod thrust col l ars.
ENGINE COMPONENTS
CYLINDER BLOCK AND BEDPLATE ASSEM-
BLY: A parti al open deck i s used for cool i ng and
wei ght reducti on wi th water pump mol ded i nto the
bl ock. Nomi nal wal l thi ckness i s 4 mm. The bedpl ate
i ncorporates mai n beari ng caps. Rear seal retai ner i s
i ntegral wi th the bl ock.
CRANKSHAFT: A nodul ar cast i ron crankshaft i s
used. The engi ne has 5 mai n beari ngs, wi th number
3 fl anged to control thrust. The 52 mm di ameter
mai n and 48 mm di ameter crank pi n journal s (al l )
have undercut fi l l et radi uses that are deep rol l ed for
added strength. To opti mi ze beari ng l oadi ng 8 coun-
terwei ghts are used. Hydrodynami c seal s provi de end
seal i ng, where the crankshaft exi ts the bl ock.
Anaerobi c gasket materi al i s used for parti ng l i ne
seal i ng. A si ntered i ron ti mi ng bel t sprocket i s
mounted on the crankshaft nose. Thi s sprocket trans-
mi ts crankshaft movement, vi a ti mi ng bel t to the
camshaft sprocket provi di ng ti med val ve actuati on.
PISTONS: The SOHC Engi ne DOES NOT have
provi si on for a free wheel i ng val ve trai n. Non free
wheel i ng val ve trai n means, i n the event of a broken
ti mi ng bel t Pi stons wi l l contact the Val ves. Al l
engi nes use pressed-i n pi ston pi ns to attach forged
powdered metal connecti ng rods. The connecti ng rods
are a cracked cap desi gn and are not repai rabl e. Hex
head cap screw are used to provi de al i gnment and
durabi l i ty i n the assembl y. Pi stons And Connecti ng
rods are servi ced as an assembl y.
PISTON RINGS: The pi ston ri ngs i ncl ude a
mol ybdenum faced top ri ng for rel i abl e compressi on
seal i ng and a taper faced i ntermedi ate ri ng for addi -
ti onal cyl i nder pressure control . Oi l Control Ri ng
Package consi st of 2 steel rai l s and a expander
spacer.
CYLINDER HEADSOHC: I t features a Si ngl e
Over Head Camshaft, four-val ves per cyl i nder cross
fl ow desi gn. The val ves are arranged i n two i nl i ne
banks, wi th the two i ntake per cyl i nder faci ng
toward the radi ator. The exhaust val ves faci ng
toward the dash panel . Rocker arm shafts mount
di rectl y to the cyl i nder head. I t i ncorporates powder
metal val ve gui des and seats. The hol l ow rocker arm
shafts suppl i es oi l to the hydraul i c l ash adjusters,
camshaft and val ve mechani sms.
CAMSHAFTSOHC: The nodul ar i ron camshaft
has fi ve beari ng journal s and 3 cam l obes per cyl i n-
der. Provi si on for cam posi ti on sensor on the cam at
the rear of cyl i nder head whi ch al so acts as thrust
pl ate. A hydrodynami c oi l seal i s used for oi l control
at the front of the camshaft.
VALVESSOHC: Four val ves per cyl i nder are
actuated by rol l er rocker arms/hydraul i c l ash adjust-
ers assembl i es whi ch pi vot on rocker arm shafts. Al l
val ves have 6 mm di ameter chrome pl ated val ve
stems. The val ve trai n has 33 mm (1.299 i nch) di am-
eter i ntake val ves and 28 mm (1.10 i nch) di ameter
exhaust val ves. Vi ton rubber val ve stem seal s are
i ntegral wi th spri ng seats. Val ve spri ngs, spri ng
retai ners, and l ocks are conventi onal desi gn.
mol ded pl asti c composi ti on, attached to the cyl i nder
head wi th ten fasteners. Thi s l ong branch desi gn
enhances l ow and mi d-range torque.
EXHAUST MANIFOLD: The exhaust mani fol d i s
made of nodul ar cast i ron for strength and hi gh tem-
peratures. Exhaust gasses exi t through a machi ned,
arti cul ated joi nt connecti on to the exhaust pi pe.
(1) Remove oi l pressure swi tch and i nstal l gauge
assembl y C-3292 wi th adaptor.
(2) Run engi ne unti l thermostat opens.
CAUTION: If oil pressure is 0 at idle, Do Not per-
form the 3000 RPM test in the next step.
(3) Oi l Pressure: Curb Idle 25 kPa (4 psi ) mi ni -
mum 3000 RPM 170-550 kPa (25-80 psi ).
Fig. 2 Engine Lubrication System SOHC
NS/GS ENGINE 9 - 3
(4) I f oi l pressure i s 0 at i dl e. Shut off engi ne,
check for pressure rel i ef val ve stuck open, a cl ogged
oi l pi ck-up screen or a damaged oi l pi ck-up tube
O-ri ng.
SERVICE PROCEDURES
CYLINDER BORE AND PISTON SIZING
round and taper wi th Tool C-119 (Fi g. 3). The cyl i n-
der bore out-of-round i s 0.050 mm (.002 i nch)
i nch) maxi mum. I f the cyl i nder wal l s are badl y
scuffed or scored, the cyl i nder bl ock shoul d be
rebored and honed, and new pi stons and ri ngs fi tted.
Whatever type of bori ng equi pment i s used, bori ng
and honi ng operati on shoul d be cl osel y coordi nated
wi th the fi tti ng of pi stons and ri ngs i n order that
speci fi ed cl earances may be mai ntai ned. Refer to
Honing Cylinder Bores outlined in the Stan-
dard Service Procedures for specification and
procedures.
10 mm (3/8 i nch) down and bottom measurement
shoul d be 10 mm (3/8 i nch.) up from bottom of bore.
Refer to Cyl i nder Bore and Pi ston Speci fi cati ons
Chart.
SIZING PISTONS
Pi ston and cyl i nder wal l must be cl ean and dry.
Pi ston di ameter shoul d be measured 90 degrees to
pi ston pi n about 17.5 mm (11/16 i nch) from the bot-
tom of the ski rt as shown i n (Fi g. 4). Cyl i nder bores
shoul d be measured hal fway down the cyl i nder bore
and transverse to the engi ne crankshaft center l i ne
shown i n (Fi g. 3). Refer to Cyl i nder Bore and Speci -
fi cati ons Tabl e. Correct pi ston to bore cl earance must
be establ i shed i n order to assure qui et and economi -
cal operati on.
Chrysl er engi nes use pi stons desi gned speci fi cal l y
for each engi ne model . Cl earance and si zi ng l ocati ons
vary wi th respect to engi ne model .
NOTE: Pistons and cylinder bores should be mea-
sured at normal room temperature, 21C (70F).
posi ti oni ng at l east 12 mm (0.50 i nch) from bottom of
SPECIFICATION CHART
Standard Bore Maximum
Out-of-Round
Maximum
Taper
87.5 mm
(3.445 in.)
0.051 mm
(0.002 in.)
0.051 mm
(0.002 in.)
Federal
Emission:
87.463 - 87.481 mm
(3.4434 - 3.4441 in.)
Low Emission
Vehicle (LEV):
87.456 - 87.474 mm
(3.4432 - 3.4439 in.)
Piston to Bore Clearance
Federal
Emission:
0.012 - 0.044 mm
(0.0004 - 0.0017 in.)
Low Emission
Vehicle (LEV):
0.18 - 0.050 mm
(0.0008 - 0.0020 in.)
Measurements Taken at Piston Size Location
Fig. 4 Piston Measurements
9 - 4 ENGINE NS/GS
(2) Check pi ston ri ng to groove si de cl earance (Fi g.
6). Refer to Pi ston Ri ng Speci fi cati on Chart.
FITTING CONNECTING RODS
(1) Fol l ow the procedure speci fi ed i n the Standard
Servi ce Procedures Secti on for Measuri ng Mai n Bear-
i ng Cl earance and Connecti ng Rod Beari ng Cl ear-
ance (Fi g. 7). Refer to speci fi cati ons.
NOTE: The rod bearing bolts should not be reused.
(2) Before i nstal l i ng the NEW bol ts the threads
shoul d be oi l ed wi th cl ean engi ne oi l .
(3) I nstal l each bol t fi nger ti ght than al ternatel y
torque each bol t to assembl e the cap properl y.
(4) Ti ghten the bol ts to 27 Nm PLUS 1/4 turn (20
ft. l bs. PLUS 1/4 turn) Do not use a torque
wrench for last step.
(5) Usi ng a feel er gauge, check connecti ng rod si de
cl earance (Fi g. 8). Refer to Connecti ng Rod Speci fi ca-
ti on Chart for speci fi cati ons.
Fig. 5 Piston Ring Gap
Ring Position Ring Gap Ring Gap Wear
Limit
Groove Clearance Maximum Groove
Clearance
(0.009 - 0.020 in.)
0.8 mm (0.031 in.) 0.025 - 0.065 mm
(0.0010 - 0.0026 in.)
0.10 mm (0.004 in.)
(0.019 - 0.031 in.)
1.0 mm (0.039 in.) 0.025 - 0.065 mm
(0.0010 - 0.0026 in.)
0.10 mm (0.004 in.)
(0.009 - 0.026 in.)
1.0 mm (0.039 in.) Oil Ring Side Rails Must Be Free To Rotate After
Assembly
Fig. 7 Connecting Rod Bearing Clearance
Fig. 8 Connecting Rod Side Clearance
NS/GS ENGINE 9 - 5
FITTING CRANKSHAFT BEARINGS
Refer to Measuri ng Mai n Beari ng Cl earance i n
Standard Servi ce Procedures. Refer to Crankshaft
Speci fi cati on Chart for speci fi cati ons.
CRANKSHAFT END PLAY
DIAL INDICATOR METHOD
travel .
cati on Chart for speci fi cati ons.
FEELER GAGE METHOD
cap and a crankshaft cheek, usi ng care not to dam-
age any beari ng surface. Do not l oosen mai n beari ng
cap.
(2) Use a feel er gauge between number three
thrust beari ng and machi ned crankshaft surface to
determi ne end pl ay.
CYLINDER HEAD COVER
REMOVAL
(1) Remove i gni ti on coi l pack (Fi g. 10).
(2) Remove the cyl i nder head cover bol ts.
(3) Remove cyl i nder head cover from cyl i nder
head.
INSTALLATION
Before i nstal l ati on, cl ean cyl i nder head and cover
mati ng surfaces. Make certai n the cyl i nder head
cover mati ng surface i s fl at.
(1) I nstal l new val ve cover gasket.
CAUTION: Do not allow oil or solvents to contact
the timing belt as they can deteriorate the rubber
and cause tooth skipping.
(2) I nstal l cover assembl y to head and ti ghten fas-
teners to 12 Nm (105 i n. l bs.).
(3) I nstal l i gni ti on coi l pack. Ti ghten fasteners to
23 Nm (200 i n. l bs.).
Connecting Rod Bearing Oil Clearance
New Part: 0.026 - 0.059 mm (0.001 - 0.0023 in.)
New Part: 0.13 - 0.38 mm (0.005 - 0.015 in.)
Crankshaft End-Play New Part: 0.09 - 0.24 mm (0.0035 - 0.0094 in.)
Main Bearing Clearance New Part: 0.022 - 0.062 mm (0.0008 - 0.0024 in.)
Connecting Rod Bearing Clearance New Part: 0.026 - 0.059 mm (0.001 - 0.0023 in.)
Main Bearing Journal Diameter Standard: 52.000 0.008 mm (2.0472 0.0003 in.)
1st Undersize: 51.983 0.008 mm
(2.0466 0.0003 in.)
Connecting Rod Journal Diameter Standard: 48.000 0.008 mm (1.8897 0.0003 in.)
1st Undersize: 47.983 0.008 mm
(1.8891 0.0003 in.)
Fig. 9 Checking Crankshaft End Play Dial
Indicator
9 - 6 ENGINE NS/GS
SPARK PLUG TUBE
(1) Remove val ve cover. Refer to procedure out-
(2) Usi ng l ocki ng pl i ers remove the tube from the
cyl i nder head (Fi g. 11). Di scard ol d tube.
(3) Cl ean area around spark pl ug wi th Mopar
parts cl eaner or equi val ent.
(4) Appl y Mopar Stud and Beari ng Mount or
equi val ent to a new tube approxi matel y 1 mm from
the end i n a 3 mm wi de area.
(5) I nstal l seal er end of tube i nto the cyl i nder
head. Then careful l y i nstal l the tube usi ng a hard-
wood bl ock and mal l et unti l the tube i s seated i nto
the bottom of the bore.
(6) I nstal l val ve cover. Refer to procedure outl i ned
i n thi s secti on.
SPARK PLUG TUBE SEALS
The spark pl ug tube seal s are l ocated i n the cyl i n-
der head cover (Fi g. 12). These seal s are pressed i nto
the cyl i nder head cover to seal the outsi de peri meter
of the spark pl ug tubes. I f these seal s show si gns of
hardness and/or cracki ng they shoul d be repl aced.
CAMSHAFT
NOTE: TO REMOVE CAMSHAFT THE CYLINDER
HEAD MUST BE REMOVED.
REMOVAL
before attempting any repairs. Refer to Group 14,
Fuel System
(2) Remove the cyl i nder head cover. Refer to proce-
(3) Mark rocker arm shaft assembl i es so that they
are i nstal l ed i n thei r ori gi nal posi ti ons.
(4) Remove rocker arm shaft bol ts. Refer to proce-
(5) Remove ti mi ng bel t, ti mi ng bel t tensi oner, and
camshaft sprocket. Refer to ti mi ng bel t servi ce out-
(6) Remove i nner ti mi ng bel t cover.
(7) Remove cyl i nder head. Refer to procedure out-
(8) Remove camshaft sensor and camshaft target
magnet.
(9) Remove camshaft from the rear of cyl i nder
head.
INSPECT CYLINDER HEAD FOR THE FOLLOWING:
NOTE:
Check oil feed holes for blockage.
Inspect cylinder head camshaft bearings for
wear, Refer to Cylinder Head, Inspection and Clean-
ing.
Check camshaft bearing journals for scratches
and worn areas. If light scratches are present, they
may be removed with 400 grit sand paper. If deep
Fig. 10 Ingition Coil Pack
Fig. 11 Servicing Spark Plug Tubes
Fig. 12 Spark Plug Tube Seals
NS/GS ENGINE 9 - 7
scratches are present, replace the camshaft and
check the cylinder head for damage. Replace the
cylinder head if worn or damaged. Check the lobes
for pitting and wear. If the lobes show signs of
wear, check the corresponding rocker arm roller for
wear or damage. Replace rocker arm/hydraulic lash
adjuster if worn or damaged. If lobes show signs of
pitting on the nose, flank or base circle; replace the
camshaft.
INSTALLATION
(1) Lubri cate the camshaft journal s wi th oi l and
i nstal l camshaft without rocker arm assembl i es
i nstal l ed.
(2) I nstal l camshaft target magnet i nto the end of
the camshaft. Ti ghten mounti ng screw to 3.4 Nm (30
i n. l bs.).
(3) I nstal l camshaft posi ti on sensor and ti ghten
mounti ng screws to 9 Nm (80 i n. l bs.).
(4) Measure camshaft end pl ay usi ng the fol l owi ng
procedure:
Mount di al i ndi cator C-3339 or equi val ent, to a
stati onary poi nt on cyl i nder head (Fi g. 13).
Usi ng a sui tabl e tool , move camshaft to rear-
ward l i mi ts of travel .
Zero the di al i ndi cator.
Move camshaft forward to l i mi ts of travel and
read di al i ndi cator.
End pl ay travel : 0.13 - 0.33 mm (0.005 - 0.013
i n.).
(5) I nstal l front camshaft seal . Camshaft must be
i nstal l ed before the camshaft seal i s i nstal l ed. Refer
to procedure outl i ned i n thi s secti on.
(6) I nstal l cyl i nder head. Refer to procedure out-
(7) I nstal l camshaft sprocket and ti ghten to 115
Nm (85 ft. l bs.).
(8) I nstal l i nner ti mi ng bel t cover.
(9) I nstal l ti mi ng bel t tensi oner and ti mi ng bel t.
Refer to procedures outl i ned i n thi s secti on.
(10) I nstal l rocker arm assembl i es i n correct order
as removed. Ti ghten the rocker arm assembl i es i n
sequence shown i n (Fi g. 14) to 28 Nm (250 i n. l bs.).
(11) I nstal l cyl i nder head cover and ti ghten fasten-
ers to 12 Nm (105 i n. l bs.).
(12) I nstal l i gni ti on coi l pack and i gni ti on cabl es.
(13) Perform camshaft and crankshaft ti mi ng
rel earn procedure as fol l ows:
Connect the DRB scan tool to the data l i nk
(di agnosti c) connector. Thi s connector i s l ocated i n
the passenger compartment; at the l ower edge of
i nstrument panel ; near the steeri ng col umn.
Turn the i gni ti on swi tch on and access the mi s-
cel l aneous screen.
Sel ect re-l earn cam/crank opti on and fol l ow
di recti ons on DRB screen.
ROCKER ARM/HYDRAULIC LASH ADJUSTER
REMOVAL
(1) Remove val ve cover usi ng procedure outl i ned i n
thi s secti on.
(2) I denti fy the rocker arm shaft assembl i es before
removal .
(3) Loosen the attachi ng fasteners. Remove rocker
arm shaft assembl i es from cyl i nder head.
(4) I denti fy the rocker arms spacers and retai ners
for reassembl y. Di sassembl e the rocker arm assem-
bl i es by removi ng the attachi ng bol ts from the shaft
(Fi g. 15).
(5) Sl i de the rocker arms and spacers off the shaft.
Keep the spacers and rocker arms i n the same l oca-
ti on for reassembl y.
Fig. 13 Camshaft End Play
Fig. 14 Rocker Arm Shaft Tightening Sequence
9 - 8 ENGINE NS/GS
NOTE: Inspect the rocker arm for scoring, wear on
the roller or damage to the rocker arm (Fig. 16)
Replace if necessary. Check the location where the
rocker arms mount to the shafts for wear or dam-
age. Replace if damaged or worn. The rocker arm
shaft is hollow and is used as a lubrication oil duct.
Check oil holes for clogging with small wire, clean
as required. Lubricate the rocker arms and spacers.
Install onto shafts in their original position (Fig. 15).
INSTALLATION
CAUTION: Set crankshaft to 3 notches before TDC
before installing rocker arm shafts. Refer to Timing
Belt System and Camshaft Seal Service of this sec-
tion for procedure.
(1) I nstal l rocker arm/hydraul i c l ash adjuster
assembl y maki ng sure that adjusters are at l east
parti al l y ful l of oi l . Thi s i s i ndi cated by l i ttl e or no
pl unger travel when the l ash adjuster i s depressed. I f
there i s excessi ve pl unger travel . Pl ace the rocker
arm assembl y i nto cl ean engi ne oi l and pump the
pl unger unti l the l ash adjuster travel i s taken up. I f
travel i s not reduced, repl ace the assembl y. Hydraul i c
l ash adjuster and rocker arm are servi ced as an
assembl y.
(2) I nstal l rocker arm and shaft assembl i es wi th
NOTCH i n the rocker arm shafts poi nti ng up and
toward the ti mi ng bel t si de of the engi ne (Fi g. 17).
I nstal l the retai ners i n thei r ori gi nal posi ti ons on the
exhaust and i ntake shafts (Fi g. 15).
CAUTION: When installing the intake rocker arm
shaft assembly be sure that the plastic spacers do
not interfere with the spark plug tubes. If the spac-
ers do interfere rotate until they are at the proper
angle. To avoid damaging the spark plug tubes, do
not attempt rotating the spacers by forcing down
the shaft assembly.
(3) Ti ghten bol ts to 28 Nm (250 i n. l bs.) i n
sequence shown i n (Fi g. 18).
Fig. 15 Rocker Arm Shaft Assemblies
Fig. 16 Rocker Arm Assemblies
Fig. 17 Rocker Arm Shaft Notches
Fig. 18 Rocker Arm Shaft Tightening Sequence
NS/GS ENGINE 9 - 9
HYDRAULIC LASH ADJ USTER NOISE
A tappet-l i ke noi se may be produced from several
i tems. Refer to Lash Adjuster Noi se - Di agnosi s i n
Standard Servi ce Procedures, outl i ned i n thi s Group.
Lash adjusters are replaced with the rocker
arm as an assembly.
VALVE SEALS AND SPRINGS IN VEHICLE
REMOVAL
(1) Remove rocker arm shafts assembl i es as previ -
ousl y outl i ned i n thi s secti on.
(2) Rotate crankshaft unti l pi ston i s at TDC on
compressi on.
(3) Wi th ai r hose attached to adapter tool i nstal l ed
i n spark pl ug hol e, appl y 90-120 psi ai r pressure.
(4) Usi ng Speci al Tool MD-998772A wi th adapter
6779 (Fi g. 19) compress val ve spri ngs and remove
val ve l ocks.
(5) Remove val ve spri ng.
(6) Remove val ve stem seal by usi ng a val ve stem
seal tool (Fi g. 20).
INSTALLATION
(1) I nstal l val ve seal /val ve spri ng seat assembl y
as outl i ned i n the Val ve I nstal l ati on procedure i n thi s
secti on.
(2) Usi ng Speci al Tool MD-998772A compress val ve
spri ngs onl y enough to i nstal l l ocks. Correct al i gn-
ment of tool i s necessary to avoi d ni cki ng val ve stems
(ai r pressure requi red), pi ston at TDC.
(3) I nstal l rocker arm shaft assembl i es as previ -
ousl y outl i ned i n thi s secti on.
(4) I nstal l val ve cover as previ ousl y outl i ned i n
thi s secti on.
CYLINDER HEAD
REMOVAL
before attempting any repairs. Refer to Group 14,
Fuel System
i ng system. Refer to Group 7, Cool i ng System.
(3) Di sconnect al l vacuum l i nes, el ectri cal wi ri ng
and fuel l i nes from throttl e body.
(4) Remove throttl e l i nkage.
Cool i ng System for procedure.
(6) Remove power brake vacuum hose from i ntake
mani fol d.
(7) Rai se vehi cl e and remove exhaust pi pe from
mani fol d.
(8) Remove power steeri ng pump assembl y and set
asi de.
(9) Di sconnect coi l pack wi ri ng connector and
remove coi l pack and bracket from engi ne.
(10) Remove cyl i nder head cover.
(11) Remove cam sensor and fuel i njectors wi ri ng
connectors.
(12) Remove i ntake mani fol d. Removal procedure
outl i ne i n Group 11.
Fig. 19 Removing and Installing Valve Spring
Fig. 21 Valve Spring Assembly
9 - 10 ENGINE NS/GS
(13) Remove ti mi ng bel t and camshaft sprocket.
(14) Remove rocker arm shaft assembl i es.
(15) Remove cyl i nder head bol ts.
NOTE: Inspect camshaft bearing journals for scor-
ing. Cylinder head must be flat within 0.1 mm (0.004
inch) (Fig. 22).
INSTALLATION
(1) Before i nstal l i ng the bol ts the threads shoul d
be oi l ed wi th engi ne oi l . The 4 short bol ts 110 mm
(4.330 i n.) are to be i nstal l ed i n posi ti ons 7, 8, 9, and
10 (Fi g. 23).
(2) Ti ghten the cyl i nder head bol ts i n the sequence
shown i n (Fi g. 23). Usi ng the 4 step torque method,
ti ghten accordi ng to the fol l owi ng val ues:
Fi rst Al l to 34 Nm (25 ft. l bs.)
Second Al l to 68 Nm (50 ft. l bs.)
Thi rd Al l to 68 Nm (50 ft. l bs.)
Fourth Turn an addi ti onal 1/4 Turn, Do not use
a torque wrench for this step.
For the rest of i nstal l ati on, reverse removal proce-
dure.
TIMING BELT COVER
REMOVAL
Cool i ng System for procedure outl i ned i n that sec-
ti on.
(2) Remove crankshaft vi brati on damper. Refer to
procedure outl i ned i n thi s secti on for removal .
(3) Remove front ti mi ng bel t cover (Fi g. 24).
Cylinder Head and Valve Assembly
NS/GS ENGINE 9 - 11
INSTALLATION
(1) I nstal l front ti mi ng cover.
(2) I nstal l crankshaft vi brati on damper Refer to
procedure outl i ned i n thi s secti on for i nstal l ati on.
Cool i ng System Accessory Dri ve secti on for proce-
dure.
CAMSHAFT OIL SEAL
REMOVAL
CAUTION: Do Not Rotate the camshaft or crank-
shaft when timing belt is removed damage to the
engine may occur.
(1) Remove ti mi ng bel t cover and bel t. Removal
procedure i s outl i ned i n thi s secti on. Remove cam-
shaft sprocket bol t, wi th the Modi fi ed Speci al Tool
C-4687-1 as shown i n (Fi g. 25).
(2) Hol d camshaft sprocket wi th modi fi ed tool
whi l e removi ng bol t. Remove sprocket from camshaft.
(3) Remove camshaft seal usi ng Speci al Tool
C-4679A (Fi g. 26).
bore.
(4) Shaft seal l i p surface must be free of varni sh,
di rt or ni cks. Pol i sh wi th 400 gri t paper i f necessary.
Fig. 23 Cylinder Head Tightening Sequence
Fig. 24 Timing Belt Cover
Fig. 25 Modification to Special Tool
Fig. 26 Removing Camshaft Oil Seal
9 - 12 ENGINE NS/GS
INSTALLATION
(1) I nstal l camshaft seal fl ush wi th cyl i nder head
usi ng Speci al Tool MD 998306 (Fi g. 27).
(2) I nstal l camshaft sprocket retai ni ng bol t. Hol d
camshaft sprocket wi th Speci al Tool C-4687-1 (Fi g.
25) and ti ghten bol t to 115 Nm (85 ft. l bs.).
TIMING BELT SYSTEM
CHECKING BELT TIMINGCOVER INSTALLED
Remove number one spark pl ug.
Usi ng a di al i ndi cator, set number one cyl i nder
to TDC on the compressi on stroke.
Remove the access pl ug from the outer ti mi ng
bel t cover (Fi g. 28).
Check the ti mi ng mark on the camshaft
sprocket, i t shoul d al i gn wi th the arrow on the rear
REMOVALTIMING BELT
ti on.
(2) Remove crankshaft damper bol t. Remove
damper usi ng the l arge si de of Speci al Tool 1026 and
i nsert 6827-A (Fi g. 30).
Fig. 27 Installing Camshaft Seal
Fig. 29 Camshaft Timing Marks
NS/GS ENGINE 9 - 13
CAUTION: Align camshaft and crankshaft timing
marks before removing the timing belt.
(4) Loosen ti mi ng bel t tensi oner fasteners (Fi g. 33)
and remove ti mi ng bel t and tensi oner.
CAUTION: Do not loosen, tighten, or remove the
tensioner pivot bolt (Fig. 32).
CAMSHAFT AND CRANKSHAFT TIMING
PROCEDURE AND BELT INSTALLATION
SOHC ENGINE
(1) When tensi oner i s removed from the engi ne i t
i s necessary to compress the pl unger i nto the ten-
si oner body.
(2) Pl ace the tensi oner i nto a vi se equi pped wi th
soft jaws and sl owl y compress the pl unger (Fi g. 34).
CAUTION: Index the tensioner in the vise the same
way it is installed on the engine. This is to ensure
proper pin orientation when tensioner is installed
on the engine.
(3) When pl unger i s compressed i nto the tensi oner
body i nstal l a 1.9 mm (5/64) al l en wrench or pi n
through the body and pl unger to retai n pl unger i n
pl ace unti l tensi oner i s i nstal l ed.
(4) Set crankshaft sprocket to TDC by al i gni ng the
sprocket wi th the arrow on the oi l pump housi ng,
then back off to 3 notches before TDC (Fi g. 35).
Fig. 32 Tensioner Pulley Assembly
Fig. 33 Remove Timing Belt
9 - 14 ENGINE NS/GS
(5) Set camshaft to TDC by al i gni ng mark on
sprocket wi th the arrow on the rear of ti mi ng bel t
cover (Fi g. 36).
(6) Move crankshaft to 1/2 mark before TDC (Fi g.
37) for bel t i nstal l ati on.
go around the water pump sprocket and then around
the camshaft sprocket.
(8) Move crankshaft sprocket to TDC to take up
bel t sl ack. I nstal l tensi oner to bl ock but do not
ti ghten fasteners.
(9) Usi ng a torque wrench on the tensi oner pul l ey
appl y 28 Nm (250 i n. l bs.) of torque (Fi g. 38).
(10) Wi th torque bei ng appl i ed to the tensi oner
pul l ey move the tensi oner up agai nst the tensi oner
pul l ey bracket and ti ghten fasteners to 31 Nm (275
i n. l bs.) (Fi g. 38).
(11) Pul l tensi oner pl unger pi n. Pretensi on i s cor-
rect when pi n can be removed and i nstal l ed.
(12) Rotate crankshaft 2 revol uti ons and check the
al i gnment of the ti mi ng marks (Fi g. 38).
(13) I nstal l front hal f of ti mi ng cover.
Fig. 34 Compressing Timing Belt Tensioner
Fig. 35 Crankshaft Sprocket Timing
Fig. 36 Camshaft Timing Mark
Fig. 37 Adjusting Crankshaft Sprocket for Timing
Belt Installation
Fig. 38 Adjusting Timing Belt Tension
NS/GS ENGINE 9 - 15
(14) I nstal l crankshaft damper usi ng M12-1.75 x
150 mm bol t, washer, thrust beari ng and nut from
ti ghten to 142 Nm (105 ft. l bs.) (Fi g. 39).
dure.
rel earn. Refer to Group 25, Emi ssi on Control Sys-
tems for procedure.
TIMING BELTw/AUTO TENSIONERIF
EQUIPPED
CHECKING BELT TIMINGCOVER INSTALLED
Remove number one spark pl ug.
Usi ng a di al i ndi cator, set number one cyl i nder
to TDC on the compressi on stroke.
Remove the access pl ug from the outer ti mi ng
Check the ti mi ng mark on the camshaft
sprocket, i t shoul d al i gn wi th the arrow on the rear
REMOVALTIMING BELT
ti on.
(2) Rai se vehi cl e on a hoi st and remove ri ght i nner
spl ash shi el d (Fi g. 42).
i nsert 6827-A (Fi g. 30).
(4) Lower vehi cl e and pl ace a jack under engi ne.
(5) Remove ri ght engi ne mount. Refer to procedure
(6) Remove ri ght engi ne mount bracket (Fi g. 44).
CAUTION: Align camshaft and crankshaft timing
marks before removing the timing belt by rotating
the engine with the crankshaft.
(8) I nsert a 8 mm Al l en wrench i nto the bel t ten-
si oner. Before rotati ng the tensi oner i nsert the l ong
end of a 1/8 or 3 mm Al l en wrench i nto the pi n hol e
on the front of the tensi oner (Fi g. 33). Rotate the ten-
si oner countercl ockwi se wi th the Al l en wrench, whi l e
pushi ng i n l i ghtl y on the 1/8 i n. or 3 mm Al l en
wrench, unti l i t sl i des i nto the l ocki ng hol e.
CAUTION: Do not rotate the camshafts once the
timing belt has been removed or damage to valve
components may occur.
CAMSHAFT AND CRANKSHAFT TIMING PROCEDURE AND
BELT INSTALLATION SOHC ENGINE
(1) Set crankshaft sprocket to TDC by al i gni ng the
sprocket wi th the arrow on the oi l pump housi ng,
then back off to 3 notches before TDC (Fi g. 35).
(2) Set camshaft to TDC by al i gni ng mark on
sprocket wi th the arrow on the rear of ti mi ng bel t
cover (Fi g. 36).
(3) Move crankshaft to 1/2 mark before TDC (Fi g.
37) for bel t i nstal l ati on.
go around the water pump sprocket and then around
the camshaft sprocket.
(5) Move crankshaft sprocket to TDC to take up
bel t sl ack.
(6) Remove the pi n or 1/8 or 3 mm Al l en wrench
from bel t tensi oner.
(7) Rotate crankshaft 2 revol uti ons and check the
al i gnment of the ti mi ng marks (Fi g. 50).
(8) I nstal l front hal f of ti mi ng cover.
(9) I nstal l engi ne mount bracket.
(10) I nstal l Ri ght engi ne mount. Refer to proce-
(11) Remove jack from under engi ne.
dure.
(14) Rai se vehi cl e on hoi st and i nstal l ri ght i nner
spl ash shi el d.
9 - 16 ENGINE NS/GS
OIL PAN
REMOVAL
(1) Drai n engi ne oi l .
(2) Remove transmi ssi on i nspecti on cover.
(3) I f equi pped wi th ai r condi ti oni ng remove oi l fi l -
ter and adaptor. Refer to Oi l Fi l ter Adapter Removal
and I nstal l ati on i n thi s secti on.
(5) Cl ean oi l pan and al l gasket surfaces.
Fig. 41 Camshaft Timing Marks
Fig. 42 Right Inner Splash Shield
NS/GS ENGINE 9 - 17
INSTALLATION
or equi val ent at the oi l pump to engi ne bl ock parti ng
l i ne (Fi g. 52).
(2) I nstal l a new oi l pan gasket to pan.
(3) I nstal l pan and ti ghten screws to 12 Nm (105
i n. l bs.).
(4) I nstal l oi l fi l ter and adaptor.
(5) I nstal l proper amount of oi l . Wi th oi l fi l ter 4.25
Li ters (4.5 Qts.). Wi thout oi l fi l ter 3.8 Li ters (4.0
Qts.)
FRONT CRANKSHAFT OIL SEAL
REMOVAL
(1) Usi ng Speci al Tool 1026 and I nsert 6827A,
remove crankshaft damper (Fi g. 53).
(2) Remove outer ti mi ng bel t cover and ti mi ng
bel t. Refer to Ti mi ng Bel t System outl i ned i n thi s
secti on.
(3) Remove crankshaft sprocket usi ng Speci al Tool
6793 and i nsert C-4685-C2 (Fi g. 54).
bore.
Fig. 44 Right Engine Mount Bracket
Fig. 46 Timing Belt Removal
9 - 18 ENGINE NS/GS
(4) Usi ng Tool 6771 to remove front crankshaft oi l
seal (Fi g. 55). Do not damage the seal contact area
on the crankshaft.
INSTALLATION
(1) I nstal l new seal by usi ng Tool 67801 (Fi g. 56).
wi th cover.
(3) I nstal l crankshaft sprocket (Fi g. 57). Usi ng
Speci al Tool 6792.
NOTE: Make sure the word front on the sprocket
is facing you.
(4) I nstal l ti mi ng bel t and covers. Refer to Ti mi ng
Bel t System i n thi s secti on for i nstal l ati on.
(5) I nstal l crankshaft damper (Fi g. 58). Use thrust
beari ng/washer and 12M-1.75 x 150 mm bol t from
Fig. 47 Crankshaft Sprocket Timing
Fig. 48 Camshaft Timing Mark
Fig. 49 Adjusting Crankshaft Sprocket for Timing
Belt Installation
NS/GS ENGINE 9 - 19
ti ghten to 142 Nm (105 ft. l bs.)
CRANKSHAFT OIL SEALREAR
REMOVAL
(1) I nsert a 3/16 fl at bl aded screwdri ver between
the dust l i p and the metal case of the crankshaft
seal . Angl e the screwdri ver (Fi g. 59) through the dust
l i p agai nst metal case of the seal . Pry out seal .
CAUTION: Do not permit the screwdriver blade to
contact crankshaft seal surface. Contact of the
screwdriver blade against crankshaft edge (cham-
fer) is permitted.
INSTALLATION
tion of new seal.
9 - 20 ENGINE NS/GS
NOTE: When installing seal, no lube on seal is
needed.
(1) Pl ace Speci al Tool 6926-1 on crankshaft. Thi s i s
a pi l ot tool wi th a magneti c base (Fi g. 60).
(2) Posi ti on seal over pi l ot tool . Make sure you can
read the words THIS SIDE OUT on seal (Fi g. 60).
Pi l ot tool shoul d remai n on crankshaft duri ng i nstal -
l ati on of seal . Ensure that the l i p of the seal i s faci ng
towards the crankcase duri ng i nstal l ati on.
CAUTION: If the seal is driven into the block past
flush, this may cause an oil leak.
(3) Dri ve the seal i nto the bl ock usi ng Speci al Tool
6926-2 and handl e C-4171 (Fi g. 61) unti l the tool bot-
toms out agai nst the bl ock (Fi g. 62).
CRANKSHAFT
REMOVAL
(1) Remove oi l fi l ter and adapter from bedpl ate.
(2) Remove col l ar from oi l pan to transmi ssi on
housi ng.
(4) Remove crankshaft sprocket and oi l pump both
procedures outl i ned i n thi s secti on.
(5) Remove al l mai n beari ng cap and bedpl ate
bol ts from the engi ne bl ock (Fi g. 63).
(6) Usi ng a mal l et tap the bedpl ate l oose from the
engi ne bl ock dowel pi ns.
Fig. 60 Rear Crankshaft Seal and Special Tool
6926-1
NS/GS ENGINE 9 - 21
CAUTION: Do not pry up on one side of the bed-
plate. Damage may occur to cylinder block and bed-
plate alignment.
(7) Bedpl ate shoul d be removed evenl y from the
cyl i nder bl ock dowel pi ns.
(8) Li ft out crankshaft from cyl i nder bl ock. Be sure
not to damage the mai n beari ngs or journal s when
removi ng the crankshaft.
CRANKSHAFT MAIN BEARINGS LOCATION
The crankshaft i s supported i n fi ve mai n beari ngs.
Al l upper beari ng shel l s i n the crankcase have oi l
grooves. Al l l ower beari ng shel l s i nstal l ed i n the (bed-
pl ate) mai n beari ng cap are pl ai n. Crankshaft end
pl ay i s control l ed by a fl anged beari ng on the number
three mai n beari ng journal (Fi g. 64).
NOTE: The upper and lower main Bearing shells
are Not interchangeable. The lower shells have a
revised tab to prevent improper installation.
CRANKSHAFT MAIN J OURNALS INSPECTION
excessi ve wear, taper and scori ng. Li mi ts of taper or
out-of-round on any crankshaft journal s shoul d be
hel d to .025 mm (.001 i nch). Journal gri ndi ng shoul d
not exceed .305 mm (.012 i nch) under the standard
journal di ameter. DO NOT gri nd thrust faces of
Number 3 mai n beari ng. DO NOT ni ck crank pi n or
beari ng fi l l ets. After gri ndi ng, remove rough edges
from crankshaft oi l hol es and cl ean out al l passages.
standard and the fol l owi ng undersi zed: 0.016 mm
(.0006 i nch), .032 mm (.0012 i nch), .250 mm (.010
i nch). Never i nstal l an undersi ze beari ng that wi l l
reduce cl earance bel ow speci fi cati ons.
INSTALLATION
cati on groove i n the cyl i nder bl ock. I nstal l O-ri ng
i nto recess i n the bl ock (Fi g. 65).
hol e i n beari ngs and beari ng tabs seat i n the bl ock
tab sl ots.
CAUTION: Do Not get oil on the bedplate mating
surface. It will affect the sealer ability to seal the
bedplate to cylinder block.
Fig. 61 Crankshaft Seal Special Tool 6926-2
Fig. 62 Rear Crankshaft SealInstallation
9 - 22 ENGINE NS/GS
crankshaft and O-ri ng i n cyl i nder bl ock.
engine.
(4) Appl y 1.5 to 2.0 mm (0.059 to 0.078 i n.) bead of
Mopar Torque Cure Gasket Maker to cyl i nder bl ock
(6) Before i nstal l i ng the bol ts oi l threads wi th
cl ean engi ne oi l , wi pe off any excess oi l .
bol ts 11, 17 and 20 fi nger ti ght. Ti ghten thi s bol ts
der bl ock. Torque bol ts to 30 Nm (22 ft. l bs.) (Fi g.
67).
Fig. 63 Bedplate Bolts Fig. 64 Main Bearing Identification
NS/GS ENGINE 9 - 23
bol ts (1 thru 10) and torque each bol t to 81 Nm (60
ft. l bs.) i n sequence shown i n (Fi g. 67).
bol ts (11 thru 20), wi th baffl e studs i n posi ti ons 12,
13 and 16 and torque each bol t to 30 Nm (22 ft. l bs.)
i n sequence shown i n (Fi g. 67).
(11) I nstal l oi l pump. I f crankshaft end pl ay i s to
be checked refer to servi ce procedures i n thi s secti on.
(12) I nstal l crankshaft sprocket.
(13) I nstal l oi l fi l ter adapter and fi l ter.
(14) I nstal l oi l pan and col l ar. Refer to procedures
outl i ned i n the secti on.
OIL FILTER ADAPTER
REMOVE AND INSTALL
Ensure O-ri ng i s i n the groove on adapter. Al i gn
rol l pi n i nto engi ne bl ock and ti ghten assembl y to 80
Nm (60 ft. l bs.) (Fi g. 68).
OIL FILTER
REMOVE AND INSTALL
CAUTION: When servicing the oil filter (Fig. 69)
avoid deforming the filter, install tool band strap
against the seam at the base of the filter. The seam,
joining the can to the base is reinforced by the
base plate.
(1) Turn countercl ockwi se to remove.
(2) To i nstal l , l ubri cate new fi l ter gasket. Check
fi l ter mounti ng surface. The surface must be smooth,
fl at and free of debri s or ol d pi eces of rubber. Screw
Sequence
Fig. 68 Engine Oil Filter Adapter to Engine Block
9 - 24 ENGINE NS/GS
fi l ter on unti l gasket contacts base. Ti ghten to 21
Nm (15 ft. l bs.).
OIL PUMP
REMOVAL
(2) Remove Ti mi ng Bel t. Refer to Ti mi ng Bel t Sys-
tem, i n thi s secti on.
(3) Remove Oi l Pan. Refer to Oi l Pan Removal i n
thi s secti on.
(4) Remove Crankshaft Sprocket usi ng Speci al Tool
6793 and i nsert C-4685-C2 (Fi g. 70).
(5) Remove oi l pi ck-up tube.
(6) Remove oi l pump (Fi g. 71) and front crankshaft
seal .
INSTALLATION
(1) Make sure al l surfaces are cl ean and free of oi l
and di rt.
(2) Appl y Mopar Gasket Maker to oi l pump as
shown i n (Fi g. 72). I nstal l ori ng i nto oi l pump body
di scharge passage.
(3) Pri me oi l pump before i nstal l ati on.
(4) Al i gn oi l pump rotor fl ats wi th fl ats on crank-
shaft as you i nstal l the oi l pump to the bl ock.
NOTE: Front crankshaft seal MUST be out of pump
to align, or damage may result.
(5) Torque al l oi l pump attachi ng bol ts to 28 Nm
(250 i n. l bs.)
(6) I nstal l new front crankshaft seal usi ng Speci al
Tool 6780 (Fi g. 73).
(7) I nstal l crankshaft sprocket, usi ng Speci al Tool
6792 (Fi g. 74).
(8) I nstal l oi l pump pi ck-up tube and oi l pan.
i n thi s secti on.
REMOVAL
matchi ng cyl i nder number (Fi g. 75).
(2) Remove oi l pan. Scri be the cyl i nder number on
the si de of the rod and cap (Fi g. 76) for i denti fi cati on.
(3) Pi stons wi l l have a stampi ng i n the approxi -
mate l ocati on shown i n (Fi g. 75). These stamps wi l l
be ei ther a di recti onal arrow or a wei ght i denti fi ca-
ti on for the assembl y. L i s for l i ght and H i s for
heavy. These assembl i es shoul d al l be the same
wei ght cl ass. Servi ce pi ston assembl i es are marked
wi th a S and can be used wi th ei ther L or H produc-
ti on assembl i es. The wei ght desi gnati on stamps
shoul d face toward the ti mi ng bel t si de of the engi ne.
(5) Remove connecti ng rod cap bol ts Do not use
old bolts if reinstalling connecting rod. Push
each pi ston and rod assembl y out of cyl i nder bore.
i ng rod.
(7) Pi ston and Rods are servi ced as an assembl y.
PISTON RINGREMOVAL
(1) I D mark on face of upper and i ntermedi ate pi s-
ton ri ngs must poi nt toward pi ston crown.
Fig. 69 Engine Oil Filter
NS/GS ENGINE 9 - 25
(2) Usi ng a sui tabl e ri ng expander, remove upper
and i ntermedi ate pi ston ri ngs (Fi g. 77).
(3) Remove the upper oi l ri ng si de rai l , l ower oi l
ri ng si de rai l and then oi l ri ng expander from pi ston.
(4) Cl ean ri ng grooves of any carbon deposi ts.
(1) I nstal l ri ngs wi th manufacturers I .D. mark fac-
i ng up, to the top of the pi ston (Fi g. 78).
order:
Fig. 71 Oil Pump and Tube
Fig. 72 Oil Pump Sealing
Fig. 73 Front Crankshaft SealInstallation
9 - 26 ENGINE NS/GS
f. I nstal l the si de rai l by pl aci ng one end between
the pi ston ri ng groove and the expander. Hol d end
fi rml y and press down the porti on to be i nstal l ed
unti l si de rai l i s i n posi ti on. Do not use a piston
ring expander (Fig. 79).
si de rai l .
ri ng (Fi g. 78).
(4) Posi ti on pi ston ri ng end gaps as shown i n (Fi g.
80).
(5) Posi ti on oi l ri ng expander gap at l east 45 from
the si de rai l gaps but not on the pi ston pi n center or
Fig. 75 Piston Markings
Fig. 77 Piston RingsRemoving and Installing
Fig. 78 Piston Ring Installation
Fig. 79 Installing Side Rail
NS/GS ENGINE 9 - 27
on the thrust di recti on. Staggeri ng ri ng gap i s i mpor-
tant for oi l control .
PISTON AND ROD INSTALLATION
oi l ri ng rai l gap.
(Fi g. 81). Be sure position of rings does not
change during this operation.
(4) The wei ght stamp desi gnati on L or H wi l l be i n
the front hal f of the pi ston shoul d face toward the
front of the engi ne for SOHC engi ne. The arrow
shoul d face toward the front of the engi ne for DOHC
engi ne (Fi g. 75).
rod and pi ston assembl y i nto cyl i nder bore and gui de
rod over the crankshaft journal .
(7) I nstal l rod caps. I nstal l New bol ts and ti ghten
to 27 Nm (20 ft.l b.) Pl us 1/4 turn.
VIBRATION DAMPER
NOTE: If a gap is found in the crankshaft damper,
in the area where the Poly-V Generator belt rides
this is normal and is acceptable (Fig. 82).
REMOVAL
ti on.
i nsert 6827A (Fi g. 83).
Fig. 81 Installing Piston
Fig. 82 Weld Gap
9 - 28 ENGINE NS/GS
INSTALLATION
dure.
OIL PUMP
(2) Remove the threaded pl ug and gasket from the
oi l pump (Fi g. 85).
CAUTION: Oil pump pressure relief valve must be
installed as shown in (Fig. 85) or serious damage
may occur.
(3) Remove spri ng and rel i ef val ve (Fi g. 85).
cover.
(6) Wash al l parts i n a sui tabl e sol vent and i nspect
VALVE SERVICE WITH THE CYLINDER HEAD
REMOVED
REMOVAL
spri ngs usi ng Speci al Tool C-3422-B or equi val ent.
VALVE INSPECTION
(.002 i n.), repl ace val ve.
VALVE GUIDES
Chart for speci fi cati ons. Repl ace gui des i f they are
not wi thi n speci fi cati on.
(1) Whenever val ves have been removed for i nspec-
ti on, recondi ti oni ng or repl acement, val ve spri ngs
Fig. 86 Oil Pump
NS/GS ENGINE 9 - 29
shoul d be tested Speci al Tool C-647. As an exampl e,
the compressi on l ength of the spri ng to be tested i s
33.34 mm (1-5/16 i nches). Turn tool tabl e unti l sur-
face i s i n l i ne wi th the 33.34 mm (1-5/16 i nch) mark
on the threaded stud and the zero mark on the front.
Pl ace spri ng over stud on the tabl e and l i ft compress-
i ng l ever to set tone devi ce (Fi g. 89). Pul l on torque
wrench unti l pi ng i s heard. Take readi ng on torque
wrench at thi s i nstant. Mul ti pl y thi s readi ng by two.
Thi s wi l l gi ve the spri ng l oad at test l ength. Frac-
ti onal measurements are i ndi cated on the tabl e for
fi ner adjustments. Di scard the spri ngs that do not
meet speci fi cati ons. The Fol l owi ng speci fi cati ons
appl y to both i ntake and exhaust val ve spri ngs.
Val ve Cl osed Nomi nal Force 67 l bs. @ 39.8 mm
(1.57 i n.)
Val ve Open Nomi nal Force 160 l bs. @ 32.6 mm
(1.28 i n.)
(2) Veri fy spri ngs are not di storted wi th a steel
square and surface pl ate, check spri ngs from both
ends. I f the spri ng i s more than 1.5 mm (1/16 i nch)
out of square, i nstal l a new spri ng.
(1) The i ntake and exhaust val ve seats and val ve
face have a 45 degree angl e.
are refaced (Fi g. 90). I ntake val ves wi th l ess than
0.95 mm (1/32 i nch.) margi n and Exhaust val ves
wi th l ess than 1.05 mm (3/64 i nch) margi n shoul d be
di scarded.
obtai ned. For val ve speci fi cati ons see Val ve Speci fi ca-
ti on Chart.
(4) Measure the concentri ci ty of val ve seat and
val ve gui de usi ng a val ve seat runout di al i ndi cator.
Valve Guide
Diameter
5.975 - 6.000 mm
(0.2352 - 0.2362
in.)
5.975 - 6.000 mm
(0.2352 - 0.2362 in.)
New: 0.023 - 0.066 mm
(0.001 - 0.0025 in.)
0.051 - 0.094 mm
(0.002 - 0.0037 in.)
Service Limit: 0.25 mm (0.010 in.)
Fig. 89 Valve Spring Testing
Fig. 90 Intake and Exhaust Valve Refacing
9 - 30 ENGINE NS/GS
Total runout shoul d not exceed. 0.051 mm (0.002
i nch.) (total i ndi cator readi ng).
(5) I nspect the val ve seat wi th Prussi an bl ue to
ferred to top edge of the val ve face, l ower val ve seat
wi th a 15 degrees stone. I f the bl ue i s transferred to
the bottom edge of val ve face rai se val ve seat wi th a
65 degrees stone.
I ntake val ve seat di ameter i s 33 mm (1.299 i n.)
Exhaust val ve seat di ameter i s 28 mm (1.102
i n.)
(6) Val ve seats whi ch are worn or burned can be
reworked, provi ded that correct angl e and seat wi dth
are mai ntai ned. The i ntake val ve seat must be ser-
vi ced when the val ve seat wi dth i s 2.0 mm (0.079 i n.)
or greater. The exhaust val ve seat must be servi ced
when the val ve seat wi dth i s 2.5 mm (0.098 i n.) or
greater. Otherwi se the cyl i nder head must be
repl aced.
i ntake and exhaust seats shoul d be 0.75 to 1.25 mm
(0.030 to 0.049 i n.) (Fi g. 91).
(8) Check val ve ti p to spri ng seat di mensi ons A
after gri ndi ng the val ve seats or faces. Gri nd val ve
ti p to 43.51 - 44.57 mm (1.71 - 1.75 i n.) for exhaust
val ve and 45.01 - 46.07 mm (1.77 - 1.81 i n.) for
i ntake val ve over spri ng seat when i nstal l ed i n the
head (Fi g. 92). The val ve ti p chamfer may need to be
reground to prevent seal damage when the val ve i s
i nstal l ed.
CLEANING
Cl ean al l val ve gui des, val ves and val ve spri ng
assembl i es thoroughl y wi th sui tabl e cl eani ng sol uti on
before reassembl i ng.
VALVE INSTALLATION
(2) I nstal l new val ve stem seal s on al l val ves usi ng
a val ve stem seal tool (Fi g. 93). The val ve stem seal s
shoul d be pushed fi rml y and squarel y over val ve
gui de.
CAUTION: If oversize valves are used, there is only
one oversize valve available. The same stem seal is
used on both the standard and oversize valve.
Face Angle
Intake and
Exhaust:
45 - 45 1/2
Head Diameter
Intake: 33.12 - 33.37 mm (1.303 - 1.313 in.)
Exhaust: 28.57 - 28.83 mm (1.124 - 1.135 in.)
Length (Overall)
Intake: 114.69 - 115.19 mm (4.515 - 4.535 in.)
Exhaust: 116.94 - 117.44 mm (4.603 - 4.623 in.)
Stem Diameter
Intake: 5.934 - 5.952 mm (0.2337 - 0.2344 in.)
Exhaust: 5.906 - 5.924 mm (0.2326 - 0.2333 in.)
Valve Margin
Intake: 1.15 - 1.48 mm (0.0452 - 0.0582 in.)
Exhaust: 1.475 - 1.805 mm (0.0580 - 0.0710 in.)
Fig. 91 Valve Seat Refacing
Fig. 92 Spring Installed Height and Valve Tip to
Spring Seat Dimensions
NS/GS ENGINE 9 - 31
can become dislocated. Check to make sure both
locks are in their correct location after removing
tool.
than 40.18 mm (1.58 i n.), i nstal l a 0.762 mm (0.030
i n.) spacer under the val ve spri ng seat to bri ng
(5) I nstal l rocker arm shafts as previ ousl y
descri bed i n thi s secti on.
(6) Checki ng dry l ash. Dry l ash i s the amount of
cl earance that exi sts between the base ci rcl e of an
i nstal l ed cam and the rocker arm rol l er when the
adjuster i s drai ned of oi l and compl etel y col l apsed.
Speci fi ed dry l ash i s 1.17 mm (0.046 i n.) for i ntake
and 1.28 mm (0.050 i n.) for exhaust. After performi ng
dry l ash check, refi l l adjuster wi th oi l and al l ow 10
mi nutes for adjuster/s to bl eed down before rotati ng
cam.
CYLINDER HEAD AND CAMSHAFT JOURNALS
INSPECTING CYLINDER HEAD
Cyl i nder head must be fl at wi thi n 0.1 mm (0.004
i nch) (Fi g. 94).
I nspect cyl i nder head camshaft beari ngs for wear.
Check camshaft journal s for scratches and worn
areas. I f l i ght scratches are present, they may be
removed wi th 400 gri t sand paper. I f deep scratches
are present, repl ace the camshaft and check the cyl -
i nder head for damage. Repl ace the cyl i nder head i f
worn or damaged. Check the l obes for pi tti ng and
wear. I f the l obes show si gns of wear, check the cor-
respondi ng rocker arm rol l er for wear or damage.
Repl ace rocker arm/hydraul i c l ash adjuster i f worn or
damaged. I f l obes show si gns of pi tti ng on the nose,
fl ank or base ci rcl e; repl ace the camshaft.
CLEANING
Remove al l gasket materi al from cyl i nder head and
bl ock. Be careful not to gouge or scratch the al umi -
num head seal i ng surface.
OIL PUMP
the oi l pump shoul d be smooth. Repl ace pump cover
i f scratched or grooved.
face (Fi g. 95). I f a 0.076 mm (0.003 i nch.) feel er
gauge can be i nserted between cover and strai ght
edge, cover shoul d be repl aced.
I f outer rotor thi ckness measures 7.64 mm (0.301
i nch.) or l ess (Fi g. 96), or i f the di ameter i s 79.95 mm
(3.148 i nches) or l ess, repl ace outer rotor.
9 - 32 ENGINE NS/GS
(4) I f i nner rotor measures 7.64 mm (.301 i nch) or
(5) Sl i de outer rotor i nto pump housi ng, press to
rotor and housi ng (Fi g. 98). I f measurement i s 0.39
mm (0.015 i nch.) or more, repl ace housi ng onl y i f
outer rotor i s i n speci fi cati on.
(6) I nstal l i nner rotor i nto pump housi ng. I f cl ear-
ance between i nner and outer rotors (Fi g. 99) i s .203
mm (.008 i nch) or more, repl ace both rotors.
pump housi ng, between bol t hol es. I f a feel er gauge
of .102 mm (.004 i nch) or more can be i nserted
assembl y (Fi g. 100). ONLY i f rotors are i n specs.
may be removed wi th 400-gri t wet or dry sandpaper.
between 18 and 19 pounds when compressed to 40.5
mm (1.60 i nches). Repl ace spri ng that fai l s to meet
speci fi cati ons.
(10) I f oi l pressure i s l ow and pump i s wi thi n spec-
i fi cati ons, i nspect for worn engi ne beari ngs, damaged
or mi ssi ng oi l pi ck-up tube o-ri ng, cl ogged oi l pi ck-up
tube screen, cl ogged oi l fi l ter and stuck open pres-
sure rel i ef val ve or other reasons for oi l pressure
l oss.
Housing
NS/GS ENGINE 9 - 33
CYLINDER BLOCK AND BORE
(2) I f new core pl ugs are i nstal l ed, Refer to Engi ne
Core Pl ugs outl i ned i n thi s secti on.
(3) Exami ne bl ock and cyl i nder bores for cracks or
fractures.
round and taper wi th Tool C-119 (Fi g. 101). The cyl -
i nder bore out-of-round i s 0.050 mm (.002 i nch)
i nch) maxi mum. I f the cyl i nder wal l s are badl y
scuffed or scored, the cyl i nder bl ock shoul d be
rebored and honed, and new pi stons and ri ngs fi tted.
Whatever type of bori ng equi pment i s used, bori ng
and honi ng operati on shoul d be cl osel y coordi nated
wi th the fi tti ng of pi stons and ri ngs i n order that
speci fi ed cl earances may be mai ntai ned. Refer to
Honing Cylinder Bores outlined in the Stan-
dard Service Procedures for specification and
procedures.
shoul d be 10 mm (3/8 i nch.) up from bottom of bore.
Chart for speci fi cati ons.
SPECIFICATIONS
ENGINE 2. 0L SOHC
Cylinder Block
Cyl i nder Bore Di ameter . . . 87.4924 - 87.5076 mm
(3.4446 - 3.4452.i n.)
Out-of-Round (Max.) . . . . . . . 0.051 mm (0.002 i n.)
Taper (Max.) . . . . . . . . . . . . . 0.051 mm (0.002 i n.)
Pistons (Federal Emission)
Cl earance 17.5 mm (11/16 i n.) from bottom of
ski rt . . . . . 0.012 - 0.044 mm (0.0004 - 0.0017 i n.)
Wei ght . . . . . . . 325 - 335 grams (11.47 - 11.82 oz.)
Land Cl earance (Di ametri cal ) . . 0.734 - 0.797 mm
(0.029 - 0.031 i n.)
Pi ston Length . . . . . . . . . . . . . . 64 mm (2.520 i n.)
Pi ston Ri ng Groove Depth
No. 1 . . . . . . . 3.989 - 4.188 mm (0.157 - 0.165 i n.)
No. 2 . . . . . . . 4.462 - 4.661 mm (0.176 - 0.184 i n.)
No. 3 . . . . . . . 3.847 - 4.131 mm (0.151 - 0.163 i n.)
Pistons (Low Emission VehicleLEV)
Cl earance 10.42 mm (0.42 i n.) from bottom of
ski rt . . . . . 0.018 0.50 mm (0.0008 0.0020 i n.)
Wei ght . . . . . . 320 329 grams (11.29 11.60 oz.)
Land Cl earance (Di ametri cal ) . . 0.758 0.790 mm
(0.0299 0.0312 i n.)
Pi ston Length . . . . . . . . . . . . . 55.8 mm (2.197 i n.)
No. 1 . . . . . . . 3.989 - 4.188 mm (0.157 - 0.165 i n.)
No. 2 . . . . . . . 4.462 - 4.661 mm (0.176 - 0.184 i n.)
No. 3 . . . . . . . 3.847 - 4.131 mm (0.151 - 0.163 i n.)
Piston Pins
Cl earance i n Pi ston . . . . . . . . . . 0.008 - 0.020 mm
(0.0003 - 0.0008 i n.)
I n Rod (I nterference) . . . . . . . . . 0.018 - 0.043 mm
(0.0007 - 0.0017 i n.)
SPECIFICATION CHART
Standard Bore Max. Out-of-
Round
Max. Taper
87.5 mm
(3.445 in.)
0.051 mm
(0.002 in.)
0.051 mm
(0.002 in.)
87.463 - 87.481 mm (3.4434 - 3.4441 in.)
Piston to Bore Clearance
0.012 - 0.044 mm (0.0005 - 0.0017 in.)
9 - 34 ENGINE NS/GS
Cylinder Block
Di ameter . . . . . . . . . . . . . . . . 20.998 - 21.003 mm
(0.8267 - 0.8269 i n.)
End Pl ay . . . . . . . . . . . . . . . . . . . . . . . . . . . . None
Length . . . . . 74.75 - 75.25 mm (2.943 - 2.963 i n.)
Piston Rings
Ri ng Gap Top Compressi on Ri ng . . 0.23 - 0.52 mm
(0.009 - 0.020 i n.)
Ri ng Gap 2nd Compressi on Ri ng . . 0.49 - 0.78 mm
(0.019 - 0.031 i n.)
Ri ng Gap Oi l Control
(Steel Rai l s) . . . 0.23 - 0.66 mm (0.009 - 0.026 i n.)
Ri ng Si de Cl earance Both Compressi on
Ri ngs . . . . 0.025 - 0.065 mm (0.0010 - 0.0026 i n.)
Oi l Ri ng (Pack) . . . . . . . . . . . . . 0.004 - 0.178 mm
(0.0002 - 0.0070 i n.)
Ri ng Wi dth Compressi on Ri ngs . . . 1.17 - 1.19 mm
(0.046 - 0.047 i n.)
Oi l Ri ng (Pack) . . . . . . . . . . . . . 2.854 - 3.008 mm
(0.1124 - 0.1184 i n.)
Connecting Rod
Beari ng Cl earance . . . . . . . . . . . 0.026 - 0.059 mm
(0.001 - 0.0023 i n.)
Pi ston Pi n Bore Di ameter . . . . . 20.96 - 20.98 mm
(0.8252 - 0.8260 i n.)
Large End Bore Di ameter . . . 50.991 - 51.005 mm
(2.0075 - 2.0081 i n.)
Si de Cl earance . 0.13 - 0.38 mm (0.005 - 0.015 i n.)
Total Wei ght (Less Beari ng) . 543 grams (1.20 l bs.)
Crankshaft
Connecti ng Rod Journal
Di ameter . . 47.9924 - 48.0076 mm (1.8894 - 1.8900 i n.)
Out-of-Round (Max.) . . . . . 0.0035 mm (0.0001 i n.)
Taper (Max.) . . . . . . . . . . . 0.0038 mm (0.0001 i n.)
Mai n Beari ng Di ametri cal Cl earance
No. 1 - 5 . . 0.022 - 0.062 mm (0.0008 - 0.0024 i n.)
End Pl ay . . . . 0.09 - 0.24 mm (0.0035 - 0.0094 i n.)
Di ameter . . . . . . . . . . . . . . 51.9924 - 52.0076 mm
(2.0469 - 2.0475 i n.)
Out-of-Round (Max.) . . . . . 0.0035 mm (0.0001 i n.)
Taper (Max.) . . . . . . . . . . . 0.0038 mm (0.0001 i n.)
ENGINE 2.0L SOHC
Rocker ArmShaft
Rocker Arm Shaft Di ameter . . 19.996 19.984mm
(0.786 0.7867 i n.)
Rocker ArmShaft Retainers (Width)
I ntake (Al l ) . . . . . . . . . . . . . . . 28.46 mm (1.12 i n.)
Exhaust . . . . . . . . . . . . . 1 & 5 29.20 mm (1.14i n.)
2, 3, and 4 - 40.45 mm (1.59 i n.)
Rocker Arm/Hydraulic Lash Adjuster *
Rocker Arm I nsi de Di ameter . . 20.00 20.02 mm
(0.787 0.788 i n.)
Rocker Arm Shaft Cl earance . . . 0.016 0.054 mm
(0.0006 0.0021 i n.)
Body Di ameter . . . . . . . . . . . 22.949 22.962 mm
(0.9035 0.9040 i n.)
Pl unger Travel Mi ni mum (Dry) . . . . . . . . . 2.2 mm
(0.087 i n.)
Rocker Arm Rati o . . . . . . . . . . . . . . . . . . . 1.4 to 1
Cylinder Head Camshaft Bearing Diameter
No. 1 . . . . 41.20 41.221 mm (1.622 1.6228 i n.)
No. 2 . . . . . . 41.6 41.621 mm (1.637 1.638 i n.)
No. 3 . . . . . . 42.0 42.021 mm (1.653 1.654 i n.)
No. 4 . . . . . . 42.4 42.421 mm (1.669 1.670 i n.)
No. 5 . . . . . 42.8 42.821 mm (1.685 1.6858 i n.)
Camshaft J ournal Diameter
No. 1 . . . 41.128 41.147 mm (1.619 1.6199 i n.)
No. 2 . . . . 41.528 41.547 mm (1.634 1.635 i n.)
No. 3 . . . . 41.928 41.947 mm (1.650 1.651 i n.)
No. 4 . . . . 42.328 42.374 mm (1.666 1.668 i n.)
No. 5 . . . 42.728 42.747 mm (1.682 1.6829 i n.)
Di ametri cal Beari ng Cl earance . 0.053 0.093 mm
(0.0027 0.003 i n.)
Max. Al l owabl e . . . . . . . . . . . 0.12 mm (0.0047 i n.)
End Pl ay . . . . . . . . . . 0.05 0.39 mm (0.0059 i n.)
Lift (Zero Lash )
I ntake . . . . . . . . . . . . . . . . . . . 7.2 mm (0.283 i n.)
Exhaust . . . . . . . . . . . . . . . . . 7.03 mm (0.277 i n.)
Valve Timing Exhaust Valve**
Cl oses (ATDC) . . . . . . . . . . . . . . . . . . . . . . . . 5.4
Opens (BBDC) . . . . . . . . . . . . . . . . . . . . . . . 43.7
Durati on . . . . . . . . . . . . . . . . . . . . . . . . . . . 229.1
Valve Timing Intake Valve **
Cl oses (ABDC) . . . . . . . . . . . . . . . . . . . . . . . 41.1
Opens (ATDC) . . . . . . . . . . . . . . . . . . . . . . . . 13.9
Durati on . . . . . . . . . . . . . . . . . . . . . . . . . . . 207.2
Val ve Overl ap . . . . . . . . . . . . . . . . . . . . . . . . . . 0
Cylinder Head
Materi al . . . . . . . . . . . . . . . . . . . . Cast Al umi num
Gasket Thi ckness (Compressed) . . . . . . . 1.15 mm
(0.045 i n.)
Valve Seat
Angl e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Runout (Max.) . . . . . . . . . . . . . . 0.050 mm (0.002)
Wi dth (Fi ni sh) I ntake and
Exhaust . . . . . 0.75 1.25 mm (0.030 0.049 i n.)
Valve Guide Finished
Di ameter I .D. . 5.975 6.000 mm (.235 .236 i n.)
Gui de Bore Di ameter (Std.) . . . . . 11.0 11.02 mm
(0.4330 0.4338 i n.)
Valves
Face Angl e I ntake and Exhaust . . . . . 45 45-1/2
Head Di ameter I ntake . . . . . . . 32.12 33.37 mm
(1.303 1.313 i n.)
Head Di ameter Exhaust . . . . . . 28.57 28.83 mm
(1.124 1.135 i n.)
NS/GS ENGINE 9 - 35
Valve Margin
I ntake . . . . . 1.15 1.48 mm (0.0452 0.0582 i n.)
Exhaust . . . . 1.475 1.805 mm (0.058 0.071 i n.)
Valve Length (Overall)
I ntake . . . . 114.69 115.19 mm (4.515 4.535 i n.)
Exhaust . . 109.59 110.09 mm (4.603 4.623 i n.)
Valve StemTip Height
I ntake . . . . . . . 45.01 46.07 mm (1.77 1.81 i n.)
Exhaust . . . . . . 43.51 44.57 mm (1.71 1.75 i n.)
StemDiameter
I ntake . . . . . 5.934 5.952 mm (0.234 0.234 i n.)
Exhaust . . . . 5.906 5.924 mm (0.233 0.233 i n.)
Stemto Guide Clearance
I ntake . . . 0.048 0.066 mm (0.0018 0.0025 i n.)
Exhaust . 0.0736 0.094 mm (0.0029 0.0037 i n.)
Max. Al l owabl e I ntake . . . . . 0.076 mm (0.003 i n.)
Max. Al l owabl e Exhaust . . . . 0.101 mm (0.004 i n.)
Valve Springs
Free Length (Approx.) . . . . . . 44.4 mm (1.747 i n.)
Nomi nal Force (Val ve cl osed) . 91 Nm @ 39.8 mm
(67 ft. l bs. @ 1.57 i n.)
Nomi nal Force (Val ve open) . 239 Nm @ 32.6 mm
(176 l bs. @ 1.28 i n.)
I nstal l ed Hei ght . . . . . . . . . . 40.18 mm (1.580 i n.)
* SERVI CE AS AN ASSEMBLY WI TH ROCKER
ARM.
** ALL READI NGS I N CRANKSHAFT DEGREES,
AT 0.5 mm (0.019 i n.) OF VALVE LI FT.
TORQUE CHART 2. 0L SOHC
DESCRIPTION . . . . . . . . . . . . . . . . . . . TORQUE
Bol ts . . . . . . . . . . . . . . . . . . . 9.6 Nm (85 i n. l bs.)
Camshaft Sprocket
Bol t . . . . . . . . . . . . . . . . . . . . 115 Nm (85 ft. l bs.)
Connecting Rod Cap
Bol ts . . . . . . . . . 27 Nm (20 ft. l bs.) Pl us 1/4 Turn
CollarOil Pan to Transaxle
Step 1: Col l ar to Oi l Pan Bol ts . 3 Nm (30 i n. l bs.)
Step 2: Col l ar to Transaxl e
Bol ts . . . . . . . . . . . . . . . . . . . 108 Nm (80 ft. l bs.)
Step 3: Col l ar to Oi l Pan
Bol ts . . . . . . . . . . . . . . . . . . . . 54 Nm (40 ft. l bs.)
M8 Bedpl ate Bol ts . . . . . . . . . . 30 Nm (22 ft. l bs.)
M11 Mai n Cap Bol ts . . . . . . . . 81 Nm (60 ft. l bs.)
Crankshaft Damper
Bol t . . . . . . . . . . . . . . . . . . . 142 Nm (105 ft. l bs.)
Cylinder Head
Bol ts . . . . . . . Refer To Cyl i nder Head I nstal l ati on
Cylinder Head Cover
Bol ts . . . . . . . . . . . . . . . . . . . 12 Nm (105 i n. l bs.)
Engine Mount BracketRight
Bol ts . . . . . . . . . . . . . . . . . . . . 61 Nm (45 ft. l bs.)
Engine Mounting
Bol ts . . . . . . . Refer to Engi ne Mount I nstal l ati on
Bol ts . . . . . . . . . . . . . . . . . . . 23 Nm (200 i n. l bs.)
Bol ts . . . . . . . . . . . . . . . . . . . 12 Nm (105 i n. l bs.)
Intake Manifold
Bol ts . . . . . . . . . . . . . . . . . . . 12 Nm (105 i n. l bs.)
Oil Filter Adapter
Fastener . . . . . . . . . . . . . . . . . 80 Nm (60 ft. l bs.)
Oi l Fi l ter . . . . . . . . . . . . . . . . . 20 Nm (15 ft. l bs.)
Oil Pan
Bol ts . . . . . . . . . . . . . . . . . . . 12 Nm (105 i n. l bs.)
Drai n Pl ug . . . . . . . . . . . . . . . 27 Nm (20 ft. l bs.)
Oil Pump Attaching
Bol ts . . . . . . . . . . . . . . . . . . . 28 Nm (250 i n. l bs.)
Oi l Pump Cover Fastener . . . 12 Nm (105 i n. l bs.)
Oi l Pump Pi ck-up Tube Bol t . 28 Nm (250 i n. l bs.)
Oi l Pump Rel i ef Val ve Cap . . . 41 Nm (30 ft. l bs.)
Rocker ArmShaft
Bol ts . . . . . . . . . . . . . . . . . . . 28 Nm (250 i n. l bs.)
Spark Pl ugs . . . . . . . . . . . . . . . 28 Nm (20 ft. l bs.)
Thermostat Housing
Bol ts . . . . . . . . . . . . . . . . . . . 23 Nm (200 i n l bs.)
Timing Belt Cover
Bol ts M6 . . . . . . . . . . . . . . . . 12 Nm (105 i n. l bs.)
Timing Belt Mechanical Tensioner Assembly
Bol ts . . . . . . . . . . . . . . . . . . . 28 Nm (250 i n. l bs.)
Timing Belt Hydraulic Tensioner
Pul l ey Bol t . . . . . . . . . . . . . . . 68 Nm (50 ft. l bs.)
Pi vot Bracket Bol t . . . . . . . . . . 31 Nm (23 ft. l bs.)
Tensi oner Bol ts . . . . . . . . . . . . 31 Nm (23 ft. l bs.)
Water Pump Mounting
Bol ts . . . . . . . . . . . . . . . . . . . 12 Nm (105 i n. l bs.)
SPECIAL TOOLS
ENGINE 2. 0L SOHC
Puller 1026
9 - 36 ENGINE NS/GS
Crankshaft Damper Removal Insert 6827-A
Camshaft Sprocket Remover/Installer C-4687
Camshaft Sprocket Remover/Installer Adapter
C-4687-1
Camshaft Seal Remover C-4679-A
Camshaft Seal Installer MD-998306
Crankshaft Damper Installer 6792
Valve Spring Compressor MD-998772-A
Spring Compressor Adapter 6779
NS/GS ENGINE 9 - 37
Valve Spring Compressor C-3422-B
Cylinder Bore Indicator C-119
Front Crankshaft Seal Remover 6771
Front Crankshaft Seal Installer 6780
Crankshaft Sprocket Remover 6793
Crankshaft Sprocket Remover Insert C-4685-C2
Crankshaft Sprocket Installer 6792
6926-2
9 - 38 ENGINE NS/GS
Pressure Gage C-3292
Dial Indicator C-3339
Indicator Bore Size C-119
Valve Spring Tester C-647
NS/GS ENGINE 9 - 39
2.5L VM DIESEL
INDEX
page page
GENERAL INFORMATION
ENGINE IDENTIFICATION . . . . . . . . . . . . . . . . 41
GENERAL SPECIFICATION . . . . . . . . . . . . . . . 40
LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . 41
ENGINE DIAGNOSISMECHANICAL . . . . . . . 44
ENGINE DIAGNOSISPERFORMANCE . . . . . 43
SERVICE PROCEDURES
CHANGING ENGINE OIL AND FILTER . . . . . . . 47
CHECKING OIL LEVEL . . . . . . . . . . . . . . . . . . . 47
CRANKSHAFT END PLAY . . . . . . . . . . . . . . . . 50
FITTING PISTON RING . . . . . . . . . . . . . . . . . . 50
TIMING PROCEDURE . . . . . . . . . . . . . . . . . . . 49
VALVE AND SEAT REFACING . . . . . . . . . . . . . 49
CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
CAMSHAFT BEARINGS . . . . . . . . . . . . . . . . . . 63
CRANKSHAFT MAIN BEARINGS . . . . . . . . . . . 63
CRANKSHAFTREMOVAL . . . . . . . . . . . . . . . 72
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . 55
CYLINDER HEAD COVER . . . . . . . . . . . . . . . . 54
CYLINDER LINER . . . . . . . . . . . . . . . . . . . . . . 72
ENGINE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . 53
ENGINE MOUNTFRONT . . . . . . . . . . . . . . . . 51
ENGINE MOUNTREAR . . . . . . . . . . . . . . . . . 52
ENGINE MOUNTRIGHT . . . . . . . . . . . . . . . . 51
INJECTION PUMP . . . . . . . . . . . . . . . . . . . . . . 61
MOUNTLEFT SIDE . . . . . . . . . . . . . . . . . . . . 51
OIL FILTER ADAPTER AND OIL COOLER . . . . 68
OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
OIL PUMP PRESSURE RELIEF VALVE . . . . . . 67
PISTONS AND CONNECTING ROD . . . . . . . . . 68
REAR CRANKSHAFT OIL SEAL . . . . . . . . . . . . 72
ROCKER ARMS AND PUSH RODS . . . . . . . . . 54
TIMING GEAR COVER . . . . . . . . . . . . . . . . . . . 61
TIMING GEAR COVER OIL SEAL . . . . . . . . . . . 61
VACUUM PUMP . . . . . . . . . . . . . . . . . . . . . . . . 68
VALVE SPRINGSCYLINDER HEAD NOT
REMOVED . . . . . . . . . . . . . . . . . . . . . . . . . . 55
VALVES AND VALVE SPRINGSHEAD OFF . . 60
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . 77
CRANKSHAFT MAIN BEARING . . . . . . . . . . . . 77
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . 75
CYLINDER HEAD COVERS . . . . . . . . . . . . . . . 74
CYLINDER LINER . . . . . . . . . . . . . . . . . . . . . . 78
OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
ROCKER ARMS AND PUSH RODS . . . . . . . . . 74
TIMING GEAR COVER . . . . . . . . . . . . . . . . . . . 75
VALVES AND VALVE SPRINGS . . . . . . . . . . . . 76
SPECIFICATIONS
2.5L VM DIESEL . . . . . . . . . . . . . . . . . . . . . . . . 78
TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
SPECIAL TOOLS
2.5L VM DIESEL . . . . . . . . . . . . . . . . . . . . . . . . 81
GENERAL INFORMATION
GENERAL SPECIFICATION
Type . . . . . . . . . . . . . . . . . . . . . . . . 425CLI EE (36B)
Di spl acement . . . . . . . . . . . . . . . . . . . 2.5L (2499 cc)
Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92.00 mm
Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94.00 mm
Compressi on Rati o . . . . . . . . . . . . . . . . . . . . 20.95:1
Vacuum at I dl e . . . . . . . . . . 600 mm/Hg (23.6 I n/Hg)
Thermostat Openi ng . . . . . . . . . . . . . . . . 80C2C
Generator Rati ng . . . . . . . . . . . . Bosch 50/120 Amp
Cool i ng System Capaci ty . . . . . . . . . . . . . . 9.5 Li ter
Power Steeri ng Capaci ty . . . . . . . . . . . . . 0.75 Li ter
Type . . . . . . . . . . . . . . . . . . . . . . . . 425CLI EE (36B)
Engi ne Oi l Capaci ty . . . . . 6.5 Li ters Wi th Oi l Fi l ter
Change
Ti mi ng System . Pushrod Operated Overhead val ves,
Wi th Gear-Dri ven Camshaft.
Ai r I ntake . . . . . . . . . . . . . . . . . . . . . . . . Dry Fi l ter
Fuel Feed . . . . . . . . . . . Vacuum Pump I ncorporated
i n I njecti on Pump.
Fuel System . . . . . . . . . . . . . I ndi rect Fuel I njecti on
(Precombusti on Chamber)
Combusti on Cycl e . . . . . . . . . . . . . . . . . . . . 4 Stroke
Cool i ng System . . . . . . . . . . . . . . . . . . Water Cool ed
I njecti on Pump . . . . . . . Rotary Pump El ectroni cal l y
Control l ed.
9 - 40 ENGINE NS/GS
Type . . . . . . . . . . . . . . . . . . . . . . . . 425CLI EE (36B)
Lubri cati on . Pressure Lubri cati on by Rotary Pump,
Ful l -Fl ow Fi l trati on
Engi ne Rotati on . . . . Cl ockwi se Vi ewed From Front
Cover
The engi ne model code (3-di gi t number/l etter code)
and seri al number are stamped on the forward faci ng
si de of the engi ne bl ock (Fi g. 1).
LUBRICATION SYSTEM
The pressuri zed system (Fi g. 2) uses a rotary pump
(3) l ocated i n the front of the engi ne bl ock, dri ven by
a gear whi ch meshes di rectl y wi th the crankshaft
gear. Al l the oi l sent to every l ubri cated part i s fi l -
tered. The pump sends the oi l through a pressure
rel i ef val ve (2) to the fi l ter (7) and through gal l eri es
i n the crankcase to the crankshaft beari ngs (8), cam-
shaft beari ngs (11) and turbocharger (10). The pi ston
pi ns, connecti ng rod smal l ends and i nsi des of the
pi stons are l ubri cated and cool ed by oi l sprayed out
from jets (9) i n the crankshaft mounti ng bl ocks. The
l ubri cati ng oi l i s sent to the rockers (12) through an
external pi pe (Fi g. 3). A val ve i n the fi l ter cartri dge
enabl es the oi l to be ci rcul ated even when the car-
tri dge i s cl ogged.
Sump i nl et (1). Pressure rel i ef val ve (2). Oi l pump
(3). Oi l cool er (6). Fi l ter cartri dge (7). Crankshaft
beari ngs (8). Jet val ve (9). Turbocharger beari ngs
(10). Camshaft beari ngs (11). Rockers (12).
Fig. 2 Lubrication System
Fig. 1 Engine Code Location
NS/GS ENGINE 9 - 41
Fig. 3 Lubrication Lines
9 - 42 ENGINE NS/GS
ENGINE DIAGNOSISPERFORMANCE
ENGINE WILL NOT
CRANK OR CRANKS
SLOWLY
1. Starting motor operating, but not cranking the
engine.
1. Remove the starter motor. Check for broken
flywheel teeth or a broken starter motor spring.
2. Crankshaft rotation restricted. 2. Rotate the engine to check for rotational
resistance.
3. Starting circuit connections loose or corroded. 3. Clean and tighten connections.
4. Neutral safety or starter relay inoperative. 4. Check starter relay supply voltage and proper
operation of neutral safety switch (if equipped).
Replace defective parts.
5. Battery charge low. 5. Check Battery voltage. Replace battery if a
charge cannot be held.
6. No voltage to starter solenoid. 6. Check voltage to solenoid. If necessary, replace
the solenoid.
7. Solenoid or starter motor inoperative. 7. Replace starter motor.
ENGINE CRANKS, BUT
WILL NOT START, NO
SMOKE
1. No fuel in supply tank. 1. Fill fuel supply.
2. Electrical fuel shutdown solenoid not operating. 2. Check for loose wires and verify that the fuel
shutdown solenoid is functioning. Check for fault
codes in the ECU.
3. Fuel injection system defective: Cranking speed
sensor. Loose connection between ECU and
harness. No power supply to the ECU. Loose
connection between injection pump and harness.
3. Check for fault codes at ECU. Refer to Group 14,
Fuel System for repairs procedures.
4. Air intake or exhaust plugged. 4. Remove the obstruction.
5. Fuel filter plugged. 5. Drain fuel/water separator and replace fuel filter.
6. Excessive fuel inlet restriction. 6. Check for restriction. Correct cause.
7. Injection pump not getting fuel or fuel is aerated. 7. Check fuel flow/bleed fuel system.
8. One or more injectors worn or not operating
properly.
8. Check/replace bad or improperly operating
injectors.
9. Camshaft out of time. 9. Check/correct timing chain sprocket alignment.
ENGINE HARD TO
START, OR WILL NOT
START, SMOKE FROM
EXHAUST
1. Incorrect starting procedure. 1. The fuel shutoff solenoid control must be in the
run position. Ensure the proper procedure is being
used.
2. Cranking speed to slow. 2. Check the battery, starter motor and look for
loose or corroded wiring connections.
3. Cylinder head heater plugs defective. 3. Verify system is working. Verify connection
between heater plug relay and ECU. Repair/replace
inoperative parts.
4. Insufficient intake air 4. Inspect or replace air filter and check for
obstruction in air supply.
5. Air in fuel system or the fuel supply is
inadequate.
5. Check the fuel flow through the filter and bleed
system. Locate and eliminate the air source.
6. Contaminated fuel. 6. Verify by operating the engine with clean fuel
from a temporary tank. Check for the presence of
gasoline. Drain and flush fuel supply tank. Replace
fuel/water separator filter.
7. Fuel screen plugged. 7. Check fuel screen.
8. One or more injectors worn or not operating
properly.
8. Check/replace improperly operating injectors.
9. Injector pump out of time. 9. Check pump timing. Refer to Group 14, Fuel
10. Engine compression low. 10. Check compression to identify the problem.
11. Fuel injection system defective. 11. Vacuum modulator defective causing EGR to
open in cold condition. Check for fault codes in the
ECU.
NS/GS ENGINE 9 - 43
ENGINE DIAGNOSISMECHANICAL
LUBRICATING OIL PRESSURE
LOW
1. Low oil level. 1a. Check and fill with clean engine
oil.
1b. Check for severe external oil
leaks that could reduce the
pressure.
2. Oil viscosity thin, diluted, or
wrong specification.
2. Verify the correct oil is being
used. Check for oil dilution.
3. Improperly operating pressure
switch/gauge
3. Verify the pressure switch is
functioning correctly. If not, replace
switch/gauge.
4. Relief valve stuck open. 4. Check/replace valve.
5. Plugged oil filter. 5. Change oil filter. Oil filter change
interval may need to be revised.
6. Oil cooler was replaced, shipping
plugs left in cooler.
6. Check/removed shipping plugs.
7. Worn oil pump. 7. Check/replace oil pump.
8. Suction tube loose or seal
leaking.
8. Check and replace seal.
9. Worn bearing or wrong bearing
installed.
9. Inspect and replace connecting
rod or main bearings. check and
replace piston cooling oil jet.
10. Oil jets under piston loose or
bad fit.
10. Check oil jets position.
LUBRICATING OIL LOSS 1. External oil leaks. 1. Visually inspect for oil leaks.
Repair as required.
2. Crankcase being overfilled. 2. Verify that the correct dipstick is
being used.
3. Incorrect oil specification or
viscosity.
3a. Make sure the correct oil is
being used.
3b. Look for reduced viscosity from
dilution with fuel.
3c. Review/reduce the oil change
intervals.
4. Oil cooler leak. 4. Check and replace the oil cooler.
5. High blow-by forcing oil out the
breather.
5. Check the breather tube area for
signs of oil loss.
9 - 44 ENGINE NS/GS
ENGINE DIAGNOSISMECHANICAL CONT.
LUBRICATING OIL LOSS
(CONT.)
6. Turbocharger leaking oil into the
air intake.
6. Inspect air duct for evidence of oil
transfer.
7. Piston rings not sealing (oil being
consumed by the engine).
7. Perform blow-by check. Repair as
required.
COMPRESSION KNOCKS 1. Air in fuel system. 1. Bleed the fuel system (refer to
Group 14, Fuel System).
2. Poor quality fuel or water/gasoline
contaminated fuel.
2. Verify by operating from a
temporary tank with good fuel. Clean
and flush the fuel supply tank.
Replace fuel/water separator.
3. Engine Overloaded. 3. Verify the engine load rating is not
being exceeded.
4. Improperly operating injectors. 4. Check and replace injectors.
5. Fuel injection system defective. 5a. Instrumented injection. 5b. Timing
solenoid of the fuel pump. 5c. Pre
and post heat time of the glow plugs.
Check the fault codes in the ECU.
EXCESSIVE ENGINE NOISES 1. Drive belt squeal, insufficient
tension or abnormally high loading.
1. Inspect the drive belts. Make sure
water pump pulley, generator and
power steering all turn freely.
2. Intake air and exhaust leak. 2. Refer to excessive exhaust smoke.
(Engine Diagnosis and Testing)
3. Excessive valve lash. 3. Make sure the rocker arms are not
bent. Defective hydraulic lash
adjuster.
4. Turbocharger noise. 4. Check turbocharger impeller and
turbine wheel for housing contact.
5. Power function knock. 5. Check and replace rod and main
bearings.
6. Fuel injection system defective. 6a. Instrumented injection. 6b. Timing
solenoid of the fuel pump. 6c. Pre
and post heat time of the glow plugs.
Check the fault codes in the ECU.
NS/GS ENGINE 9 - 45
ENGINE DIAGNOSISMECHANICAL CONT.
9 - 46 ENGINE NS/GS
HYDRAULIC TAPPETS
Before di sassembl i ng any part of the engi ne to cor-
rect tappet noi se, check the oi l pressure. I f vehi cl e
has no oi l pressure gauge, i nstal l a rel i abl e gauge at
the pressure sendi ng uni t. The pressure shoul d be
between 3.5 bars to 5.0 bars at 4000 RPM.
Check the oi l l evel after the engi ne reaches normal
operati ng temperature. Al l ow 5 mi nutes to stabi l i ze
oi l l evel , check di psti ck. The oi l l evel i n the pan
shoul d never be above the FULL mark or bel ow the
ADD OI L mark on di psti ck. Ei ther of these 2 condi -
ti ons coul d be responsi bl e for noi sy tappets.
OIL LEVEL HIGH
I f oi l l evel i s above the FULL mark, i t i s possi bl e
for the connecti ng rods to di p i nto the oi l . Wi th the
engi ne runni ng, thi s condi ti on coul d create foam i n
the oi l pan. Foam i n oi l pan woul d be fed to the
hydraul i c tappets by the oi l pump causi ng them to
l ose l ength and al l ow val ves to seat noi si l y.
OIL LEVEL LOW
Low oi l l evel may al l ow oi l pump to take i n ai r.
When ai r i s fed to the tappets, they l ose l ength whi ch
al l ows val ves to seat noi si l y. Any l eaks on i ntake si de
of oi l pump through whi ch ai r can be drawn wi l l cre-
ate the same tappet acti on. Check the l ubri cati on
system from the i ntake strai ner to the pump cover,
i ncl udi ng the rel i ef val ve retai ner cap. When tappet
noi se i s due to aerati on, i t may be i ntermi ttent or
constant, and usual l y more than 1 tappet wi l l be
noi sy. When oi l l evel and l eaks have been corrected,
operate the engi ne at fast i dl e. Run engi ne for a suf-
fi ci ent ti me to al l ow al l of the ai r i nsi de the tappets
to be bl ed out.
TAPPET NOISE DIAGNOSIS
(1) To determi ne source of tappet noi se, operate
engi ne at i dl e wi th cyl i nder head covers removed.
(2) Feel each val ve spri ng or rocker arm to detect
noi sy tappet. The noi sy tappet wi l l cause the affected
spri ng and/or rocker arm to vi brate or feel rough i n
operati on.
NOTE: Worn valve guides or cocked springs are
sometimes mistaken for noisy tappets. If such is
the case, noise may be dampened by applying side
thrust on the valve spring. If noise is not apprecia-
bly reduced, it can be assumed the noise is in the
tappet. Inspect the rocker arm push rod sockets
and push rod ends for wear.
(3) Val ve tappet noi se ranges from l i ght noi se to a
heavy cl i ck. A l i ght noi se i s usual l y caused by exces-
si ve l eak down around the uni t pl unger or by the
pl unger parti al l y sti cki ng i n the tappet body cyl i nder.
The tappet shoul d be repl aced. A heavy cl i ck i s
caused by a tappet check val ve not seati ng or by for-
ei gn parti cl es becomi ng wedged between the pl unger
and the tappet body. Thi s wi l l cause the pl unger to
sti ck i n the down posi ti on. Thi s heavy cl i ck wi l l be
accompani ed by excessi ve cl earance between the
val ve stem and rocker arm as val ve cl oses. I n ei ther
case, tappet assembl y shoul d be removed for i nspec-
ti on and cl eani ng.
(4) The val ve trai n generates a noi se very much
l i ke a l i ght tappet noi se duri ng normal operati on.
Care must be taken to ensure that tappets are mak-
i ng the noi se. I n general , i f more than one tappet
seems to be noi sy, i ts probabl y not the tappets.
SERVICE PROCEDURES
CHECKING OIL LEVEL
To assure proper engi ne l ubri cati on, the engi ne oi l
must be mai ntai ned at the correct l evel . Check the
oi l l evel at regul ar i nterval s, such as every fuel stop.
The best ti me to check the oi l l evel i s about 5 mi n-
utes after a ful l y warmed-up engi ne i s shut off, or
before starti ng the vehi cl e after i t has sat overni ght.
Checki ng the oi l whi l e the vehi cl e i s on l evel
ground, wi l l i mprove the accuracy of the oi l l evel
readi ngs (Fi g. 4).
CHANGING ENGINE OIL AND FILTER
Change engi ne oi l and fi l ter at mi l eage and ti me
i nterval s descri bed i n the Mai ntenance Schedul e.
Fig. 4 Checking Engine Oil
NS/GS ENGINE 9 - 47
ENGINE OIL CHANGE
WARNING: NEW OR USED ENGINE OIL CAN BE
IRRITATING TO THE SKIN. AVOID PROLONGED OR
REPEATED SKIN CONTACT WITH ENGINE OIL.
CONTAMINANTS IN USED ENGINE OIL, CAUSED BY
INTERNAL COMBUSTION, CAN BE HAZARDOUS TO
YOUR HEALTH. THOROUGHLY WASH EXPOSED
SKIN WITH SOAP AND WATER. DO NOT WASH
SKIN WITH GASOLINE, DIESEL FUEL, THINNER, OR
SOLVENTS, HEALTH PROBLEMS CAN RESULT. DO
NOT POLLUTE, DISPOSE OF USED ENGINE OIL
PROPERLY. CONTACT YOUR DEALER OR GOVERN-
MENT AGENCY FOR LOCATION OF COLLECTION
CENTER IN YOUR AREA.
Run engi ne unti l achi evi ng normal operati ng tem-
perature.
(1) Posi ti on the vehi cl e on a l evel surface and turn
engi ne off.
(2) Remove oi l fi l l cap.
(3) Hoi st vehi cl e. Refer to Hoi sti ng and Jacki ng
Recommendati ons.
(4) Pl ace a sui tabl e drai n pan under crankcase
drai n.
(5) Remove drai n pl ug from crankcase and al l ow
oi l to drai n i nto pan (Fi g. 5). I nspect drai n pl ug
threads for stretchi ng or other damage. Repl ace
drai n pl ug i f damaged.
(6) I nstal l drai n pl ug i n crankcase.
(7) Lower vehi cl e and fi l l crankcase wi th speci fi ed
type and amount of engi ne oi l .
(8) I nstal l oi l fi l l cap.
(9) Start engi ne and i nspect for l eaks.
(10) Stop engi ne and i nspect oi l l evel .
ENGINE OIL
ENGINE OIL QUALITY
Use onl y oi l s conformi ng to API (Ameri can Petro-
l eum I nsti tute) qual i ty SG/CD, or CCMC G4. Use
onl y Di esel engi ne oi l meeti ng standard MIL-2104C
or API servi ce cl assi fi cati on SG/CD or CCMM PD1 .
OIL VISCOSITY
Grade 15W-40 i s recommended for temperatures
between +35C to 10C (95F to 14F). Low vi scosi ty
oi l s must have the proper API qual i ty or the CCMC
G5 desi gnati on. Low vi scosi ty oi l s are preferred when
mi ni mum temperatures consi stentl y fal l bel ow 12C
(10F).
ENGINE OIL FILTER CHANGE
(1) Posi ti on a drai n pan under the oi l fi l ter.
(2) Usi ng a sui tabl e oi l fi l ter wrench l oosen fi l ter.
(3) Rotate the oi l fi l ter countercl ockwi se to remove
i t from the oi l fi l ter base (Fi g. 6).
(4) When fi l ter separates from base, ti p gasket end
upward to mi ni mi ze oi l spi l l . Remove fi l ter from vehi -
cl e.
(5) Wi th a cl oth, wi pe cl ean the gasket seal i ng sur-
face of oi l and gri me.
OIL FILTER INSTALLATION
(1) Li ghtl y l ubri cate oi l fi l ter gasket wi th engi ne
oi l .
(2) Thread fi l ter onto the base. When gasket
makes contact wi th seal i ng surface, hand ti ghten fi l -
ter one ful l turn, do not over ti ghten.
Fig. 5 Oil Drain Plug
Fig. 6 Oil Filter
9 - 48 ENGINE NS/GS
(3) Add oi l , veri fy crankcase oi l l evel and start
engi ne. I nspect fi l ter area for oi l l eaks.
TIMING PROCEDURE
CAUTION: If a timing gear is removed you must
loosen the rocker arm supports before rotating the
crankshaft or camshaft. This will prevent the valves
hitting the pistons.
For the engi ne components to be i n proper ti mi ng
order, the ti mi ng gear marks (dots) must be al i gned
as shown i n (Fi g. 7). To faci l i tate reassembl y, al i gn
the ti mi ng marks as shown i n (Fi g. 7), or mark the
ti mi ng gear posi ti ons before removal of any marked
gears or gear dri ven component(s).
VALVE AND SEAT REFACING
VALVE REFACING
(1) Use a val ve refaci ng machi ne to reface the
i ntake and exhaust val ves to the speci fi ed angl e.
(2) After refaci ng, a margi n of at l east 4.52-4.49
mm (.178-.177 i nch) must remai n (Fi g. 8). I f the mar-
gi n i s l ess than 4.49 mm (.177 i nch), the val ve must
be repl aced.
VALVE SEAT REFACING
(1) I nstal l a pi l ot of the correct si ze i n the val ve
gui de bore. Reface the val ve seat to the speci fi ed
angl e wi th a good dressi ng stone. Remove onl y
enough metal to provi de a smooth fi ni sh.
(2) Use tapered stones to obtai n the speci fi ed seat
wi dth when requi red.
Fig. 7 Aligning Timing Marks
Fig. 8 Valve Specification
NS/GS ENGINE 9 - 49
VALVE STAND DOWN
Val ve stand down i s to mai ntai n the adequate com-
pressi on rati o.
(1) I nvert cyl i nder head.
(2) Fi t each val ve to i ts respecti ve val ve gui de.
(3) Usi ng a strai ght edge and feel er gauge (Fi g. 9),
check val ve head stand down: I nl et val ve head stand
down .80 to 1.2 mm (.031 to .047 i n.) and exhaust
val ve stand down .79 to 1.19 mm (.031 to .047 i n).
(4) I f val ve head stand down i s not i n accordance
wi th above, di scard ori gi nal val ves, check stand down
wi th new val ves and recut val ve seat i nserts to
obtai n correct stand down.
VALVE GUIDE HEIGHT
(1) Val ve Gui des hei ght requi rement.
(2) Measurement A (Fi g. 10): 13.50 - 14.00 mm.
VALVE STEM-TO-GUIDE CLEARANCE
MEASUREMENT
(1) Measure and record i nternal di ameter of val ve
gui des. Val ve gui de i nternal di ameter i s 8.0 to 8.015
mm (.3149 to .3155 i n.).
(2) Measure val ve stems and record di ameters.
I ntake val ve stem di ameter 7.94 to 7.96 mm (.3125 to
.3133 i n). Exhaust val ve stem di ameter 7.92 to 7.94
mm (.3118 to .31215 i n).
(3) Subtract di ameter of val ve stem from i nternal
di ameter of i ts respecti ve val ve gui de to obtai n val ve
stem cl earance i n val ve gui de. Cl earance of i nl et
val ve stem i n val ve gui de i s .040 to .075 mm (.0015
to .0029 i n). Cl earance of exhaust val ve stem i n val ve
gui de i s .060 to .095 mm (.0023 to .0037 i n).
(4) I f val ve stem cl earance i n val ve gui de exceeds
tol erances, new val ve gui des must be i nstal l ed.
FITTING PISTON RING
cyl i nder bore (Fi g. 11). Check gap wi th feel er gauge.
Top compressi on ri ng gap .25 to .50mm (.0098 to
.0196 i n.). Second compressi on ri ng gap .25 to .35mm
(.0098 to .0137 i n.). Oi l control ri ng gap .25 to .58mm
(.0098 to .0228 i n.).
(2) I f ri ng gaps exceed di mensi on gi ven, new ri ngs
or cyl i nder l i ners must be fi tted. Keep pi ston ri ngs i n
pi ston sets.
Top compressi on ri ng gap .08 to .130mm (.0031 to
.0051 i n.). Second compressi on ri ng gap .070 to
.102mm (.0027 to .0040 i n.). Oi l control ri ng gap .040
to .072mm (.0015 to .0028 i n.).
CRANKSHAFT END PLAY
(1) Attach di al i ndi cator to engi ne bl ock (Fi g. 13).
(2) Move crankshaft toward front of engi ne and
zero i ndi cator.
(3) Move crankshaft toward the rear of engi ne and
record measurement.
(4) Subtract speci fi ed crankshaft end fl oat from
fi gure obtai ned. Crankshaft end fl oat 0.08 to
0.21mm.
(5) Sel ect thrust washer whi ch wi l l gi ve correct
end fl oat.
Fig. 9 Checking Valve Stand Down
Fig. 11 Ring Gap Measurement
9 - 50 ENGINE NS/GS
(6) Refer to crankshaft mai n beari ng I nstal l ati on i f
not i n speci fi cati on.
NOTE: If engine is disassembled refer to Crank-
shaft Main Bearing Removal and Installation for this
procedure.
ENGINE MOUNTFRONT
(2) Remove l ower ai r dam at front fasci a.
(3) Remove the bol ts hol di ng tow bracket and front
mount to the l ower crossmember.
(4) Remove thru bol t i n engi ne mount (Fi g. 14).
Remove mount.
(6) Torque engi ne mount thru bol t to 65 Nm (48
ft. l bs.)
(7) Torque crossmember bol ts for tow bracket and
engi ne mount to 54 Nm (40 ft. l bs.)
ENGINE MOUNTRIGHT
(1) Remove the ri ght engi ne mount top support
bracket bol t (Fi g. 15).
(3) Remove the engi ne mount to frame bol ts.
(4) Remove the thru bol t from the mount assembl y.
Remove i nsul ator
(5) I f repl acei ng or removi ng ri ght engi ne mount
bracket the torque on the mounti ng bol ts i s 40 Nm
(30 ft. l bs.)
(7) Torque engi ne mount top bol t (Verti cal ) to 101
Nm (75 ft. l bs.)
(8) Torque engi ne mount thru bol t (Hori zontal ) to
145 Nm (107 ft. l bs.)
(9) Torque engi ne mount to frame bol ts to 68 Nm
(50 ft. l bs.)
MOUNTLEFT SIDE
wheel .
(2) Remove i nner spl ash shi el d.
jack.
(4) Remove the i nsul ator thru bol t from the mount
(Fi g. 16).
(5) Remove the transmi ssi on mount bol ts and
remove mount. I t may be necessary to l ower trans-
mi ssi on sl i ghtl y to remove mount.
(7) I nstal l mount. Torque transmi ssi on mount bol ts
to 54 Nm (40 ft. l bs.).
(8) Al i gn mount i nto frame bracket wi th transmi s-
si on jack, i nstal l thru bol t. Torque thru bol t to 71
Nm (53 ft. l bs.).
Fig. 13 Measuring Crankshaft End Play
Fig. 14 Front Engine Mount and Tow Bracket
NS/GS ENGINE 9 - 51
ENGINE MOUNTREAR
wi th a transmi ssi on jack so i t wi l l not rotate.
(3) Remove the thru bol t from the i nsul ator at
crossmember connecti on (Fi g. 17).
(4) Remove the bol ts hol di ng the mount to the
engi ne and transmi ssi on.
(5) Di sconnect both shi fter cabl es at transmi ssi on.
Remove the retai ners hol di ng the cabl es to the
mount (Fi g. 18).
(6) Remove the mount assembl y.
(8) I nstal l mount assembl y. Torque bol ts at engi ne
and transmi ssi on to 101 Nm (75 ft. l bs.).
(9) Al i gn i nsul ator at crossmember and i nstal l
thru bol t. Torque to 68 Nm (50 ft. l bs.).
Fig. 15 Right Engine MountVM Diesel
Fig. 16 Left Side MountVM Diesel
Fig. 17 Rear Engine MountVM Diesel
9 - 52 ENGINE NS/GS
ENGINE ASSEMBLY
REMOVAL
(2) Remove the ai r cl eaner assembl y and i nl et
hose.
(3) Remove both hoses at i ntercool er and engi ne.
(4) Di sconnect EGR vacuum hose.
(5) Di sconnect brake booster vacuum hose.
(6) Di sconnect oi l pressure swi tch connector (Fi g.
19).
(7) Di sconnect Wi ri ng harness bracket at transaxl e
shi ft tower.
(8) Di sconnect transaxl e wi ri ng at speed sensor,
crank sensor, and backup l i ght swi tch.
(9) Remove both transmi ssi on shi ft cabl es at trans-
mi ssi on.
(10) Remove negati ve battery cabl e at cyl i nder
bl ock (Fi g. 19).
(11) Remove oi l separator.
(12) Remove connectors at cool ant temperature
sensor and A/C compressor.
(13) Di sconnect fuel i njecti on pump wi ri ng connec-
tors (Fi g. 19).
(14) Di sconnect gl ow pl ug connectors.
(15) Di sconnect el ectri cal connector at number 1
fuel i njector.
(17) Remove ri ght si de spl ash shi el d (Fi g. 20).
WARNING: THE COOLANT IN A RECENTLY OPER-
ATED ENGINE IS HOT AND PRESSURIZED. USE
CARE TO PREVENT SCALDING BY HOT COOLANT.
CAREFULLY RELEASE THE PRESSURE BEFORE
REMOVING THE RADIATOR DRAIN COCK AND CAP.
(18) Drai n the cool i ng system (refer to Group 7,
Cool i ng).
(20) Remove Cool ant pressure bottl e and di scon-
nect l ow cool ant l evel sensor.
(21) Di sconnect both heater hoses.
(22) Remove the l ower radi ator hose.
(23) Remove the upper radi ator hose.
(24) Remove fuel l i ne at i njector pump and cap.
(25) Remove power steeri ng reservoi r and reposi -
ti on.
(26) Remove upper radi ator crossmember.
(27) Di sconnect cool i ng fan modul e connector.
Fig. 18 Shift Cables at Rear Mount Fig. 19 Component Locations
NS/GS ENGINE 9 - 53
(28) Remove radi ator support bol ts. It is neces-
sary to loosen the receiver/dryer to gain access
to the radiator bolts.
(29) Remove radi ator and fans as an assembl y.
(30) Remove accessory dri ve bel t generator/power
steeri ng. Refer to Group 7, for procedure.
(31) Remove both power steeri ng l i nes at pump,
and cap both l i nes.
NOTE: It is not necessary to discharge A/C system
for engine removal.
(32) Remove A/C compressor. Secure compressor
away from engi ne for cl earance duri ng engi ne
removal .
(33) Remove Generator and adjusti ng bracket.
NOTE: Do not remove the mounting base from the
generator. It is aligned at the factory and cannot be
realigned in the field.
(34) Hoi st vehi cl e.
(35) Remove exhaust pi pe at turbo outl et.
(36) Remove connecti ons at starter.
(37) Remove power steeri ng hi gh pressure l i ne
bracket at rear of oi l pan.
(38) Remove both dri veshafts from transaxl e. Refer
to Group 2, Suspensi on and Dri veshafts.
(39) Di sconnect cl utch cabl e at transaxl e.
(40) Remove rei nforcement pl ate on l ower cross-
member.
(41) Remove front and rear engi ne mounts. Refer
to procedure outl i ned i n thi s secti on.
(42) Drai n engi ne oi l and remove oi l fi l ter i f neces-
sary.
(43) Mount both speci al tool , engi ne support brack-
ets VM-1026 to cyl i nder bl ock (Fi g. 21).
(44) Usi ng engi ne dol l y and cradl e assembl y wi th
4 adjustabl e posts al i gn posts wi th hol es i n the
engi ne support brackets.
(45) Lower vehi cl e so wei ght of only the engine
and transmission i s on the dol l y and cradl e assem-
bl y.
(46) Remove l eft si de spl ash shi el d to gai n access
to thru bol t for l eft si de mount.
(47) Remove ri ght engi ne mount and l eft si de
mount. Refer to procedure outl i ned i n thi s secti on.
move the engi ne/transmi ssi on assembl y on the dol l y
to al l ow for removal around body.
CYLINDER HEAD COVER
REMOVAL
(1) Di sconnect the battery cabl es.
(2) Remove generator bracket.
(3) Remove breather hose.
(4) Remove cool ant pressure tank.
INSTALLATION
(1) I nstal l cyl i nder head cover, torque nuts to 23.5
Nm (208 i n. l bs.).
(2) I nstal l cool ant pressure tank.
(3) I nstal l breather hose.
(4) I nstal l generator bracket, ti ghten bol ts to 7
Nm (4 ft. l bs.).
(5) Connect battery cabl e.
ROCKER ARMS AND PUSH RODS
REMOVAL
(1) Di sconnect the battery cabl es.
(2) Remove generator bracket.
(3) Remove breather hose.
(4) Remove cool ant pressure tank.
(6) Remove rocker retai ni ng nuts (Fi g. 22).
(7) Remove rocker assembl y. Pl ace them on a
bench i n the same order as removed.
(8) Remove the push rods and pl ace them on a
INSTALLATION
(1) I nstal l the push rods i n the same order as
removed.
(2) I nstal l rocker arm assembl i es i n the same
order as removed. Ti ghten the rocker arm nuts to
29.4 Nm (264 i n. l bs.) torque.
Fig. 21 Engine Removal
9 - 54 ENGINE NS/GS
(3) I nstal l cyl i nder head cover, torque nuts to 14.7
Nm (132 i n. l bs.).
(4) I nstal l cool ant pressure tank.
(5) I nstal l breather hose.
(6) I nstal l generator bracket, ti ghten bol ts to 7
Nm (4 ft. l bs.).
(7) Connect the servi ce val ves to the A/C compres-
sor ports, i f equi pped wi th ai r condi ti oni ng.
VALVE SPRINGSCYLINDER HEAD NOT
REMOVED
Thi s procedure can be done wi th the engi ne cyl i n-
der head i nstal l ed on the bl ock.
REMOVAL
Each val ve spri ng i s hel d i n pl ace by a retai ner
and a set of coni cal val ve l ocks. The l ocks can be
removed onl y by compressi ng the val ve spri ng.
(1) Remove the engi ne cyl i nder head cover, refer to
cyl i nder head cover removal i n thi s secti on.
(2) Remove rocker arms assembl i es for access to
each val ve spri ng to be removed.
(3) Remove push rods. Retai n the push rods, and
rocker arms assembl i es i n the same order and posi -
ti on as removed.
(4) I nspect the spri ngs and retai ner for cracks and
possi bl e si gns of weakeni ng.
(5) I nstal l an ai r hose adaptor i n the fuel i njector
hol e.
(6) Connect an ai r hose to the adapter and appl y
ai r pressure sl owl y. Mai ntai n at l east 621 kPa (90
psi ) of ai r pressure i n the cyl i nder to hol d the val ves
agai nst thei r seats.
(7) Tap the retai ner or ti p wi th a rawhi de hammer
to l oosen the l ock from the retai ner. Use Val ve Spri ng
Compressor Tool to compress the spri ng and remove
the l ocks.
(8) Remove val ve spri ng and retai ner.
I nspect the val ve stems, especi al l y the grooves. An
Arkansas smooth stone shoul d be used to remove
ni cks and hi gh spots.
INSTALLATION
(1) I nstal l val ve spri ng and retai ner.
(2) Compress the val ve spri ng wi th Val ve Spri ng
Compressor Tool and i nsert the val ve l ocks. Rel ease
the spri ng tensi on and remove the tool . Tap the
spri ng from si de-to-si de to ensure that the spri ng i s
seated properl y on the engi ne cyl i nder head.
(3) Di sconnect the ai r hose. Remove the adaptor
from the fuel i njector hol e and i nstal l the fuel i njec-
tor.
(4) Repeat the procedures for each remai ni ng val ve
spri ng to be removed.
(5) I nstal l the push rods. Ensure the bottom end of
each rod i s centered i n the pl unger cap seat of the
hydraul i c val ve tappet.
(6) I nstal l the rocker arm assembl i es, at thei r ori g-
i nal l ocati on.
(7) Ti ghten the rocker arm assembl y nut to 106
(8) I nstal l the engi ne cyl i nder head cover, refer to
cyl i nder head cover i nstal l ati on i n thi s secti on.
CYLINDER HEAD
REMOVAL
(1) Di sconnect the battery cabl e.
WARNING: DO NOT REMOVE THE CYLINDER
BLOCK DRAIN PLUGS OR LOOSEN THE RADIATOR
DRAIN COCK WITH THE SYSTEM HOT AND PRES-
SURIZED BECAUSE SERIOUS BURNS FROM THE
COOLANT CAN OCCUR.
(2) Drai n the cool i ng system. Refer to Group 7,
Cool i ng.
(3) Remove wi per modul e. Refer to Group 8K,
Wi ndshi el d Wi per Uni t Removal for procedure.
(4) Remove cool ant pressure bottl e.
(5) Remove i ntercool er hose at i ntake mani fol d
(Fi g. 23).
(6) Remove i ntercool er hose at turbocharger i nter-
cool er tube.
(7) Remove the upper radi ator hose.
(8) Remove water mani fol d.
(9) Di sconnect the heater hoses and cool ant pres-
sure bottl e hoses.
Fig. 22 Rocker Arm Retaining Nut
NS/GS ENGINE 9 - 55
(10) Di sconnect EGR tube from EGR val ve (Fi g.
25).
(11) Remove exhaust pi pe from turbocharger el bow
and.
(12) Di sconnect oi l feed l i ne from turbo (Fi g. 24).
(13) Di sconnect oi l drai n l i ne from turbo.
(14) Remove I ntake mani fol d. Refer to Group 11,
Exhaust System and I ntake Mani fol d.
(15) Remove l i ft eye and brake vacuum tube at
rear of exhaust mani fol d.
(16) Remove the support strut from bl ock to turbo-
charger exhaust el bow.
(17) Remove Exhaust mani fol d. Refer to Group 11,
Exhaust System and I ntake Mani fol d.
(18) Remove oi l l i ne at pressure swi tch.
(19) Remove oi l feed l i ne for rocker arm assembl i es
(Fi g. 26).
(20) Remove Crankcase breather hose from val ve
cover
(21) Remove the engi ne cyl i nder head cover.
Fig. 23 Intercooler Assembly
Fig. 24 Turbocharger
Fig. 25 EGR Valve and Tube
Fig. 26 Rocker Arm Oil Feed Lines
9 - 56 ENGINE NS/GS
(22) Remove the i njector sensor wi re at the con-
nector, and gl ow pl ug Connectors.
NOTE: The attachment point for the injector sensor
wire at the injector is not a connector. The connec-
tor is located in the wire 4 to 6 inches away from
the injector.
(23) Remove i njector fuel l i nes from i njectors to
pump.
(24) Remove fuel i njectors wi th tool VM-1012A
(Fi g. 27) and (Fi g. 28) Refer to Group 14, Fuel Sys-
tem.
(25) Remove rocker retai ni ng nuts (Fi g. 29).
(26) Remove rocker assembl i es. Pl ace them on a
(27) Remove the push rods and pl ace them on a
(28) Mark cyl i nder heads to ensure i nstal l ati on i n
there ori gi nal posi ti on.
(29) Remove the engi ne cyl i nder head bol ts wi th
speci al tool VM-1018 and VM-1019.
(30) Remove the engi ne cyl i nder heads and gasket.
NOTE: A single steel head gasket is used for 4 cyl-
inder heads (Fig. 32).
(31) Stuff cl ean l i nt free shop towel s i nto the cyl -
i nder bores.
CYLINDER HEAD GASKET
NOTE: If cylinder wall liners have not been
removed; the same thickness head gasket removed,
may be used.
CAUTION: Piston protrusion must be measured, to
determine cylinder head gasket thickness, if one or
more cylinder wall liners have been replaced.
Cyl i nder head gaskets are avai l abl e i n three thi ck-
ness. The di fferent thi cknesses are marked wi th
i denti fi cati on hol es (one, two or none) (Fi g. 32). The
gasket i s to be i nstal l ed DRY. DO NOT use a gas-
ket sealing compound on the gasket.
(1) Use speci al tool VM-1010 wi th di al i ndi cator
speci al tool VM- 1013 (Fi g. 30).
(2) Bri ng the pi ston of cyl i nder no. 1 exactl y to top
dead center.
Fig. 27 Fuel Injector Tool VM-1012A
Fig. 28 Fuel Injector
Fig. 29 Rocker Arm Retaining Nut
NS/GS ENGINE 9 - 57
(3) Zero the di al i ndi cator on the cyl i nder bl ock
mati ng surface.
(4) Setup the di al i ndi cator on the pi ston crown
(above the center of the pi ston pi n) 5mm (1/8 i n.)
from the edge of the pi ston and note the measure-
ment (Fi g. 31).
(5) Repeat the procedure wi th the rest of the cyl -
i nders.
(6) Establ i sh the thi ckness of the gasket for al l
four cyl i nder heads on the basi s of the greatest pi s-
ton protrusi on (Fi g. 32).
INSTALLATION CYLINDER HEAD
(1) Remove the shop towel s from the cyl i nder
bores. Coat the bores wi th cl ean engi ne oi l .
(2) I nstal l cyl i nder head al i gnment studs
(VM-1009).
(3) After determi ni ng the correct head gasket
thi ckness, cl ean the bl ock and head mati ng surfaces,
pl ace the engi ne cyl i nder head gasket over the dow-
el s.
(4) Pl ace the engi ne cyl i nder head over the dowel s.
CAUTION: Engine cylinder head bolts can be
reused up to three times.
(5) Ti ghten the engi ne cyl i nder head bol ts i n
sequence accordi ng to the fol l owi ng procedure (Fi g.
33):
a. The threads and undersi de heads of the bol ts
shoul d be l ubri cated. Use the cyl i nder head al i gn-
ment studs tool number VM-1009. Posi ti on the heads
on the bl ock and secure wi th the ten l arge center
bol ts and spacers (cl amps), fi nger ti ght onl y.
b. Ensure that the vari ous cl amps are i nstal l ed
correctl y and the head gasket remai n i n thei r proper
posi ti on, compl etel y covered. Then, l ubri cate and
i nstal l the ei ght smal l bol ts, al so fi nger ti ght.
(6) Loosen assembl y oi l feed l i ne for rocker arm
assembl i es
(7) I nstal l the i ntake and exhaust mani fol ds wi th
new gaskets, parti al l y ti ghteni ng the nuts to a max-
i mum of 5 Nm (44 i n. l bs.). Thi s wi l l al i gn the heads
(refer to Group 11, Exhaust System and I ntake Man-
i fol d for the proper procedures). I nstal l l i ft eye and
brake vacuum tube at thi s ti me.
(8) Then, ti ghten the 12mm bol ts wi th speci al tool
VM-1019 i n the fol l owi ng manner:
(9) 1st Phase: Ti ghteni ng Head Bol ts (Fi g. 33).
Central bol ts (A-L): Ti ghten al l bol ts, starti ng wi th
bol t A then B-C-D-E-F-G-H-I -L, to 30 Nm. Repeat
the operati on wi th the same torque. Fol l owi ng the
same sequence rotate each bol t through an angl e of
Fig. 30 Measuring Piston Protrusion
Fig. 31 Piston Protrusion Chart
Fig. 32 Head Gasket Identification
9 - 58 ENGINE NS/GS
70 usi ng angl e torque tool . Then rotate the bol ts an
addi ti onal 70 fol l owi ng ti ghteni ng sequence.
(10) Then, ti ghten the 14mm bol ts wi th speci al
tool VM-1018 i n the fol l owi ng manner:
(11) Si de bol ts (M1-M2): Ti ghten M1 bol ts to 30
Nm, then rotate them 85 (5). Ti ghten M2 bol ts to
30 Nm, then rotate them 85 (5).
(12) 2nd Phase: After 20 mi nutes of engi ne oper-
ati on at operati ng temperature, al l ow engi ne to cool
down compl etel y. Then retorque the head bol ts as fol -
l ows:
(13) Central bol ts A-L: Starti ng from bol t A,
sl acken and retorque i t i mmedi atel y to 30 Nm + 65.
Rotate the bol t an addi ti onal 65. Then proceed i n
the same way, bol t by bol t, fol l owi ng al phabeti cal
order, as i ndi cated.
(14) Si de bol ts M1-M2: Without slackening ,
torque bol ts M1 then bol ts M2 to 90 Nm (66 ft. l bs.).
(15) Ti ghten i ntake nuts to 30 Nm (22 ft. l bs.) and
exhaust mani fol ds nuts to 30 Nm (22 ft. l bs.) speci -
fi ed torque after compl eti ng Phase 2.
(16) I f the engi ne cyl i nder head i s to be repl aced
and the ori gi nal val ves used, measure the val ve stem
di ameter. Onl y standard si ze val ves can be used wi th
a servi ce repl acement engi ne cyl i nder head unl ess
the repl acement head val ve stem gui de bores are
reamed to accommodate oversi ze val ve stems.
Remove al l carbon bui l dup and reface the val ves.
(17) Ti ghten oi l feed l i nes for rocker arm assem-
bl i es and oi l pressure swi tch to 13 Nm (112 i n. l bs.).
(18) I nstal l push rods and rocker arm assembl i es,
ti ghten nut to 29.4 Nm (264 i n. l bs.).
(19) I nstal l fuel i njectors use tool VM-1012 (refer
to Group 14, Fuel System).
(20) I nstal l val ve cover, ti ghten nuts to 14.7 Nm
(132 i n. l bs.).
(21) Connect crankcase breather hose.
(22) Connect the i njector sensor wi re connector,
and the gl ow pl ug connectors.
(23) I nstal l oi l feed l i ne, ti ghten banjo bol ts to 12.7
Nm (108 i n. l bs), and oi l drai n l i ne to turbo.
(24) I nstal l water mani fol d ti ghten bol ts to 12 Nm
(106 i n. l bs.).
(25) I nstal l exhaust pi pe to turbo el bow, ti ghten
bol ts to 28 Nm (250 i n. l bs.).
(26) I nstal l the support strut from bl ock to turbo-
charger exhaust el bow.
(27) I nstal l EGR tube to EGR val ve, ti ghten bol ts
to 26 Nm (19 ft. l bs.).
(28) I nstal l i ntercool er hoses at i ntake mani fol d.
(29) I nstal l cool ant pressure bottl e and hoses.
(30) I nstal l wi per modul e. Refer to Group 8K,
Wi ndshi el d Wi per Uni t I nstal l ati on for procedure.
(31) I nstal l i ntercool er hose at turbocharger tube.
(32) I nstal l fuel i njector l i nes from the pump to
i njectors, ti ghten nuts to 17.6 Nm (156. l bs.).
(33) Connect the upper radi ator hose.
(35) Fi l l the cool i ng system. Check for l eaks.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN DIRECT
LINE WITH THE FAN. DO NOT PUT HANDS NEAR
THE PULLEYS, BELTS OR FAN. DO NOT WEAR
LOOSE CLOTHING.
Fig. 33 Engine Cylinder Head Bolt Tightening Sequence
NS/GS ENGINE 9 - 59
(36) Operate the engi ne wi th the radi ator cap off.
I nspect for l eaks and conti nue operati ng the engi ne
unti l the thermostat opens. Add cool ant, i f requi red.
VALVES AND VALVE SPRINGSHEAD OFF
Thi s procedure i s done wi th the engi ne cyl i nder
head removed from the bl ock.
REMOVAL
(1) Remove the engi ne cyl i nder head from the cyl -
i nder bl ock. Refer to cyl i nder head removal i n thi s
secti on.
(2) Use Val ve Spri ng Compressor Tool and com-
press each val ve spri ng.
(3) Remove the val ve l ocks, retai ners, and spri ngs.
(4) Use an Arkansas smooth stone or a jewel ers
fi l e to remove any burrs on the top of the val ve stem,
especi al l y around the groove for the l ocks.
(5) Remove the val ves, and pl ace them i n a rack i n
the same order as removed.
INSTALLATION
(1) Fi t each val ve to i ts respecti ve val ve gui de.
NOTE: If valves and valve seats have been refaced
refer to Service Procedures in this section. Follow
The Valve Stand Down procedure.
(2) I nstal l l ower, washer and spri ng.
(3) I nstal l upper spri ng col l ar, and compress val ve
spri ng wi th spri ng compressor tool . I nstal l spl i t cone
retai ners.
HYDRAULIC TAPPETS
REMOVAL
(1) Remove cool ant pressure bottl e.
(2) Remove cyl i nder head cover. Refer to cyl i nder
head cover removal i n thi s secti on.
(3) Remove rocker assembl y and push rods. I den-
ti fy push rods to ensure i nstal l ati on i n ori gi nal l oca-
ti on (Fi g. 34).
(4) Remove cyl i nder head, i ntake mani fol d, and
exhaust mani fol d. Refer to cyl i nder head removal i n
thi s secti on.
(5) Remove yoke retai ner and al i gni ng yokes (Fi g.
35).
(6) Sl i de Hydraul i c Tappet Remover/I nstal l er Tool
through openi ng i n bl ock and seat tool fi rml y i n the
head of tappet.
(7) Pul l tappet out of bore wi th a twi sti ng moti on.
I f al l tappets are to be removed, i denti fy tappets to
ensure i nstal l ati on i n ori gi nal l ocati on.
(8) I f the tappet or bore i n cyl i nder bl ock i s scored,
scuffed, or shows si gns of sti cki ng, ream the bore to
next oversi ze. Repl ace wi th oversi ze tappet.
CAUTION: The plunger and tappet bodies are not
interchangeable. The plunger and valve must
always be fitted to the original body. It is advisable
to work on one tappet at a time to avoid mixing of
parts. Mixed parts are not compatible. DO NOT dis-
assemble a tappet on a dirty work bench.
INSTALLATION
(1) Lubri cate tappets.
(2) I nstal l tappets and yoke retai ners i n thei r ori g-
i nal posi ti ons. Ensure that the oi l feed hol e i n the
si de of the tappet body faces up (away from the
crankshaft).
Fig. 34 Tappet and Rocker Arm Assembly
Fig. 35 Tappet and Yoke
9 - 60 ENGINE NS/GS
(3) I nstal l cyl i nder head, i ntake mani fol d, and
exhaust mani fol d. Refer to cyl i nder head i nstal l ati on
i n thi s secti on.
(4) I nstal l push rods i n ori gi nal posi ti ons.
(5) I nstal l rocker arms i n ori gi nal posi ti ons.
(6) I nstal l cyl i nder head cover. Refer to cyl i nder
val ve cover i nstal l ati on i n thi s secti on.
(7) Start and operate engi ne. Warm up to normal
CAUTION: To prevent damage to valve mechanism,
engine must not be run above fast idle until all
hydraulic tappets have filled with oil and have
become quiet.
VIBRATION DAMPER
REMOVAL
(3) Remove ri ght si de l ower spl ash shi el d.
(4) Remove generator, power steeri ng bel t. Refer to
Group 7, Cool i ng.
(5) Remove water pump bel t. Refer to Group 7,
Cool i ng.
(6) Remove engi ne starter. Refer to Group, 8B for
procedure
(7) I nstal l fl ywheel l ocki ng tool VM.1014 to pre-
vent engi ne rotati on.
NOTE: Crankshaft damper nut is left handed
thread.
(8) Remove vi brati on damper nut.
(9) Remove vi brati on damper. No speci al tool i s
needed for removal .
CAUTION: If thread sealant is used it is important
to remove all the old thread sealant from the
threads on the crankshaft.
INSTALLATION
NOTE: Before installing damper be sure the O-ring
inside the center of the damper is in its grove.
(1) I nstal l vi brati on damper.
CAUTION: Correct torque on the vibration damper
nut is important or engine damage can occur.
(2) I nstal l vi brati on damper nut and ti ghten to 441
Nm (325 ft. l bs.).
(3) Remove fl ywheel l ocki ng tool , and i nstal l
engi ne starter.
(4) I nstal l both accessary dri ve bel ts. Refer to
Group 7, Cool i ng.
(5) I nstal l ri ght spl ash shi el d.
(7) Connect the battery cabl e.
TIMING GEAR COVER OIL SEAL
REMOVAL
(2) Remove vi brati on damper. Refer to vi brati on
damper removal i n thi s secti on.
(3) Pry out seal (Fi g. 36).
INSTALLATION
Remove the oi l seal ri ng. The seati ng di ameter
must be 68.000 - 68.030 mm.
(1) I nstal l new seal usi ng speci al tool VM-1015.
(2) I nstal l vi brati on damper. Refer to vi brati on
damper i nstal l ati on i n thi s secti on.
(3) Connect the battery cabl e.
INJECTION PUMP
For removal and i nstal l ati on of i njecti on pump
refer to Group 14, Fuel .
TIMING GEAR COVER
REMOVAL
(3) Remove ri ght spl ash shi el d.
(4) Remove accessary dri ve bel ts. Refer to Group 7,
Cool i ng.
(5) Remove vi brati on damper nut.
thread.
(6) Remove vi brati on damper.
Fig. 36 Front Cover Seal
NS/GS ENGINE 9 - 61
(7) Remove power steeri ng/ai r condi ti oni ng pul l ey
nut. Remove pul l ey.
CAUTION: Remove old loctite from threads on
pump.
(8) Remove pump shaft support bracket assembl y.
(9) Di sconnect the water drai n pi pe hose at the
ti mi ng cover.
CAUTION: When separating the timing geat cover
from the block take care not to damage the mating
surface of the timing gear cover or block. Also take
care not to damage the timing gears or components
located inside the timing gear cover near the edge.
(10) Remove ti mi ng gear cover.
INSTALLATION
(1) Appl y a conti nuous 3 mm bead of Si l i cone
Seal er to ti mi ng cover, i nstal l wi thi n 10 mi nutes,
ti ghten Torx bol ts to 11 Nm (96 i n. l bs) (Fi g. 37).
(2) I nstal l pump shaft support bracket assembl y,
ti ghten nuts to 24.5 Nm (216 i n. l bs.).
(3) I nstal l Power steeri ng/ai r condi ti oni ng pul l ey,
ti ghten to 170 Nm (125 ft. l bs.).
CAUTION: Correct torque on the power steering/air
conditioning pulley nut is important or engine dam-
age can occur.
(4) Connect water drai n pi pe hose at the ti mi ng
cover.
NOTE: Before installing damper be sure O-ring on
inside center of damper is in place.
(5) I nstal l vi brati on damper.
(6) Ti ghten vi brati on damper nut to 441 Nm (325
ft. l bs.).
(7) I nstal l accessary dri ve bel ts. Refer to Group 7,
cool i ng for procedure.
(8) I nstal l spl ash shi el d.
CAMSHAFT
REMOVAL
(1) To servi ce the camshaft (Fi g. 38) the engi ne
must be removed from the vehi cl e.
(2) Remove val ve cover. Refer to val ve cover
(3) Remove rocker arms and push rods. I denti fy
push rods to ensure i nstal l ati on i n there ori gi nal
l ocati on.
(4) Remove cyl i nder head. Refer to cyl i nder head
(5) Remove hydraul i c tappets. Refer to tappet
(6) Remove vi brati on damper. Refer to vi brati on
damper removal i n thi s secti on.
(7) Remove power steeri ng pul l ey.
(8) Remove pump shaft support bracket.
(9) Remove ti mi ng gear cover. Refer to ti mi ng gear
cover removal i n thi s secti on.
(10) Remove camshaft.
Fig. 37 Front Cover Sealer Location
Fig. 38 Camshaft Assembly
9 - 62 ENGINE NS/GS
THRUST PLATE INSPECTION
Check the thi ckness (Fi g. 40) of the pl ate at poi nts
a-b-c-d. I f the measurement i s not between 3.950 -
4.050 i t must be changed.
INSTALLATION
(1) Coat the camshaft journal s wi th cl ean engi ne
oi l and careful l y i nstal l the camshaft compl ete wi th
thrust pl ate and gear. Ti ghten the retai ni ng bol ts to
24 Nm. Be sure to al i gn the ti mi ng marks as shown.
(2) I nstal l hydraul i c tappets and retai ni ng yokes.
(3) I nstal l cyl i nder heads.
(4) Push rods, and rocker arm assembl i es. I n there
ori gi nal l ocati on.
(5) I nstal l val ve cover.
(6) I nstal l Ti mi ng case cover.
(7) I nstal l Vi brati on damper.
(8) Rei nstal l Engi ne.
CAMSHAFT BEARINGS
Thi s procedure requi res that the engi ne i s removed
from the vehi cl e.
REMOVAL
(1) Wi th engi ne compl etel y di sassembl ed, dri ve out
rear cam beari ng core hol e pl ug.
(2) I nstal l proper si ze adapters and horseshoe
washers (part of Camshaft Beari ng Remover/I nstal l er
Tool ) at back of each beari ng shel l . Dri ve out beari ng
shel l s.
INSTALLATION
(1) I nstal l new camshaft beari ngs wi th Camshaft
Beari ng Remover/I nstal l er Tool by sl i di ng the new
camshaft beari ng shel l over proper adapter.
(2) Posi ti on rear beari ng i n the tool . I nstal l horse-
shoe l ock and by reversi ng removal procedure, care-
ful l y dri ve beari ng shel l i nto pl ace.
(3) I nstal l remai ni ng beari ngs i n the same man-
ner. Beari ngs must be careful l y al i gned to bri ng oi l
hol es i nto ful l regi ster wi th oi l passages from the
mai n beari ng. I f the camshaft beari ng shel l oi l hol es
are not i n exact al i gnment, remove and i nstal l them
correctl y. I nstal l a new core hol e pl ug at the rear of
camshaft. Be sure this plug does not leak.
CRANKSHAFT MAIN BEARINGS
REMOVAL
(1) Di sconnect battery cabl e.
(2) Remove engi ne from vehi cl e, refer to engi ne
(3) I nstal l engi ne to engi ne stand.
(4) Remove accessary dri ve system.
(5) Remove cyl i nder head cover, refer to cyl i nder
head cover removal i n thi s secti on.
(6) Remove rocker arm and push rods, refer to
rocker arm and push rod secti on i n thi s secti on.
(7) Remove i ntake, exhaust mani fol d and turbo-
charger, refer to Group 11, Exhaust System and
I ntake Mani fol d.
(8) Remove water mani fol d.
(9) Remove oi l feed l i nes to rocker arms.
(10) Remove cyl i nder heads.
(11) Remove oi l pan and oi l pi ck-up.
(12) Remove pi ston and connecti ng rods from
crankshaft journal s.
Fig. 39 Camshaft Removal
Fig. 40 Camshaft Thrust Plate
NS/GS ENGINE 9 - 63
(13) Remove pi stons and connecti ng rods from
bl ock.
(14) Remove vi brati on damper. Refer to procedure
i n thi s secti on.
(15) Remove front cover. Refer to procedure i n thi s
secti on.
(16) Remove oi l pump dri ve gear.
(17) I nstal l speci al tool VM-1004 onto crankshaft
over gear (Fi g. 41).
(18) Remove mai n beari ng oi l feed and carri er
l ocators from bl ock.
(19) Remove fl ywheel and adaptor pl ate from
engi ne bl ock.
(20) Remove thrust beari ngs from rear mai n bear-
i ng carri er (Fi g. 42).
(21) Sl i de crankshaft and beari ng carri ers rear-
ward to rear of bl ock. I f you encounter di ffi cul ty i n
removi ng the compl ete assembl y as previ ousl y
descri bed, sl i de the assembl y rearward suffi ci entl y to
gai n access to the mai n beari ng carri er bol ts. Mark
the carri ers for assembl y and remove the bol ts, two
for each carri er (Fi g. 43).
(22) Separate the two hal ves of each carri er,
remove from the crankshaft and temporari l y re-as-
sembl e the carri ers (Fi g. 44). Wi thdraw the crank-
shaft through the rear of the crankcase.
INSTALLATION
NOTE: Assemble engine according to sequence
described, thus saving time and preventing dam-
ages to engine components. Clean parts with a suit-
able solvent and dry them with compressed air
before assembly. Use new gaskets where applicable
and torque wrenches for correct tightening of com-
ponents.
(1) Thoroughl y cl ean crankcase and oi l passages,
and bl ow dry wi th compressed ai r.
(2) I nstal l new mai n beari ng shel l s i n each of the
carri er hal ves. Assembl e the carri ers to the crank-
shaft journal s, ensuri ng that the carri ers are
i nstal l ed i n thei r ori gi nal l ocati ons. Secure each car-
ri er wi th the two bol ts ti ghteni ng evenl y to 42 Nm
(31 ft. l bs.) (Fi g. 44).
(3) Sl i de speci al tool (VM-1002) over the crank-
shaft gear and, i nsert the crankshaft and carri er
assembl y i nto the crankcase i n the same manner
used for removal .
(4) Al i gn the hol es i n the l ower carri ers, wi th the
center of the crankcase webs (Fi g. 45).
(5) Secure each carri er assembl y to the crankcase
wi th the mai n beari ng oi l feed and carri er l ocators
and ti ghten them to 54 Nm (40 ft. l bs).
(6) I nstal l rear mai n beari ng carri er onto crank-
shaft ensuri ng arrow on beari ng carri er al i gns wi th
verti cal web i n center of crankcase.
(7) I nstal l rear oi l seal .
(8) I nstal l new O-ri ngs i n adaptor pl ate.
(9) I nstal l adaptor pl ate and ti ghten bol ts to 47
Nm (35 ft. l bs.).
(10) I nstal l bol ts to mai n beari ng carri er and
ti ghten to 26.5 Nm (20 ft. l bs.).
(11) Posi ti on fl ywheel and O-ri ng on crankshaft
and al i gn bol t hol es.
NOTE: For purposes of checking crankshaft end
play used flywheel bolts may be used. Final assem-
bly requires new flywheel bolts.
(12) I nstal l 2 fl ywheel bol ts, 180 apart, and
ti ghten bol ts to 20 Nm pl us 60 (15 ft. l bs.) pl us 60.
(13) Attach di al i ndi cator to engi ne bl ock.
(14) Move crankshaft toward front of engi ne and
zero i ndi cator.
(15) Move crankshaft toward the rear of engi ne
and record measurement.
(16) Subtract speci fi ed crankshaft end pl ay from
fi gure obtai ned. Crankshaft end pl ay 0.08 to 0.21 mm
(0.0032 to 0.0083 i n.).
(17) Sel ect thrust washers whi ch wi l l gi ve correct
end pl ay.
(18) Remove tool s and fl ywheel .
(19) Lubri cate thrust washer hal ves and fi t them
i nto the rear mai n beari ng carri er.
(20) To veri fy correct end pl ay, i nstal l 2 fl ywheel
bol ts 180 apart, and ti ghten bol ts to 20 Nm pl us 60
(15 ft. l bs. pl us 60).
(21) Measure crankshaft end pl ay wi th a di al
gauge. Crankshaft end pl ay shoul d not exceed 0.08-
Fig. 41 Crankshaft Special Tool VM.1004
9 - 64 ENGINE NS/GS
0.21 mm (0.0032 to 0.0083 i n.) (Fi g. 46). I f end cl ear-
ance exceeds these val ues i nstal l oversi ze thrust
washer.
CAUTION: Use NEW flywheel bolt for the following
procedure.
(22) I nstal l new O-ri ng on fl ywheel . I nstal l fl y-
wheel . The 6 fl ywheel bol ts must be ti ghtened as fol -
l ows:
a. Torque the 6 fl ywheel bol ts to 60 Nm (44 ft.
l bs.).
b. Loosen 2 of the 6 bol ts, 180 apart. Torque the 2
bol ts to 20 Nm (180 i n. l bs.). Then usi ng a torque
angl e gauge rotate the 2 bol ts 65 addi ti onal .
c. Loosen the next 2 bol ts, 180 apart and fol l ow
the same procedure.
d. Loosen the l ast 2 bol ts, 180 apart and fol l ow
the same procedure.
(23) I nstal l Transmi ssi on. Refer to procedure i n
Group 21, Transmi ssi on.
(24) I nstal l pi stons and connecti ng rod assembl i es,
refer to pi ston and connecti ng rods i n thi s secti on.
(25) I nstal l oi l pi ck up tube and ti ghten bol ts to 25
Nm (18 ft. l bs.).
(26) I nstal l oi l pan, refer to oi l pan i nstal l ati on i n
thi s secti on.
(27) I nstal l vacuum pump. Ti ghten retai ni ng
screws to 20 Nm (15 ft. l bs.).
Fig. 42 Crankshaft and Bearings
Fig. 43 Carrier Bolts
Fig. 44 Crankshaft and Carrier Bearing Assembly
NS/GS ENGINE 9 - 65
CAUTION: The vacuum pump must be centered in
the block and tighten with two bolts. Ensure that
the pump spins freely. If vacuum pump drags or
does not spin freely loosen bolts and perform pro-
cedures again.
(28) Before i nstal l i ng oi l pump check pump bore
depth i n bl ock (A) and pump body hei ght (B) (Fi g.
47). Di fference between A and B shoul d be
0.020-0.082 mm (.0007 to 0032 i n.).
(29) I nstal l oi l pump and ti ghten retai ni ng screws
to 27 Nm (20 ft. l bs.). Check for normal backl ash
between pump and crankshaft gears.
(30) I nstal l oi l pump dri ve Gear.
(31) I nstal l front cover. Refer to procedure i n thi s
secti on.
(32) I nstal l vi brati on damper. Refer to procedure
i n thi s secti on.
(33) I nstal l cyl i nder heads. Refer to procedure i n
thi s secti on.
(34) I nstal l rocker arms and push rods. Refer to
(35) I nstal l cyl i nder head cover. Refer to procedure
i n thi s secti on.
(36) I nstal l accessary dri ve system.
(37) I nstal l engi ne i n vehi cl e. Refer to procedure i n
thi s secti on.
(38) Fi l l engi ne wi th the correct amount of fl ui ds
speci fi ed.
OIL PAN
REMOVAL
(1) Di sconnect battery cabl e.
Fig. 45 Main Bearing Carrier Alignment
Fig. 46 Measuring Crankshaft End Play
Fig. 47 Oil Pump Bore Depth
9 - 66 ENGINE NS/GS
(3) Drai n oi l .
(4) Remove oi l pan bol ts (Fi g. 48).
INSTALLATION
(1) I nstal l oi l pan. Appl y a conti nuous 3 mm bead
of Si l i cone Seal er to oi l pan, i nstal l wi thi n 10 mi n-
utes.
(2) I nstal l oi l pan bol ts and torque bol ts to 11 Nm
(8 ft. l bs.).
(3) I nstal l oi l drai n pl ug ti ghten to 79 Nm (58 ft.
l bs).
(5) Fi l l engi ne wi th proper amount of oi l .
OIL PUMP
REMOVAL
(2) Remove ri ght spl ash shi el d.
(3) Remove both accessory dri ve bel ts. Refer to
Group 7, Cool i ng.
(4) Remove pump shaft support bracket assembl y.
(5) Remove vi brati on damper. Refer to Vi brati on
Damper Removal i n thi s secti on.
thread.
(6) Remove front cover. Refer to Ti mi ng Gear
Cover Removal i n thi s secti on.
(7) Remove oi l pump.
INSTALLATION
(1) I nstal l new O-ri ng and l ubri cate wi th cl ean
engi ne oi l .
(2) I nstal l oi l pump and ti ghten retai ni ng screws
to 27.5 Nm (240 i n. l bs.).
(3) I nstal l front cover. Refer to Ti mi ng Gear Cover
I nstal l ati on i n thi s secti on.
(4) I nstal l pump shaft support bracket assembl y.
(5) I nstal l vi brati on damper. Torque nut to 441
Nm (325 ft. l bs.)
(6) I nstal l both accessory dri ve bel ts. Refer to
Group 7, Cool i ng.
(7) I nstal l ri ght spl ash shi el d.
OIL PUMP PRESSURE RELIEF VALVE
REMOVAL
(2) Remove cl i p retai ni ng rel i ef val ve.
(3) Remove rel i ef val ve cap, spri ng, and pl unger
(Fi g. 50).
(4) Check rel i ef val ve spri ng l ength. Rel i ef val ve
spri ng free l ength i s 57.5mm (2.263 i n.). I f spri ng
l ength i s l ess or spri ng i s di storted i t must be
repl aced.
(5) Check pl unger for scori ng, repl ace i f necessary.
INSTALLATION
(1) Thoroughl y cl ean al l components and rel i ef
val ve pocket i n cyl i nder bl ock.
(2) Fi t pl unger, spri ng and cap i nto bl ock.
(3) Compress spri ng and i nstal l retai ni ng cl i p.
Ensure cl i p i s compl etel y seated i n groove.
Fig. 48 Oil Pan
Fig. 49 Oil Pump Drive Gear
NS/GS ENGINE 9 - 67
OIL FILTER ADAPTER AND OIL COOLER
REMOVAL
(1) Remove oi l fi l ter.
(2) Remove oi l cool er adapter bol t.
(3) Remove oi l cool er (Fi g. 51).
INSTALLATION
(1) I nstal l oi l cool er wi th new gasket, ti ghten oi l
cool er adapter bol t to 60 Nm (44 ft. l bs.).
(2) I nstal l oi l fi l ter adapter to oi l cool er and
ti ghten to 49 Nm (36. l bs.).
(3) I nstal l oi l fi l ter and ti ghten to 9.8 Nm (85 i n.
l bs.) and add oi l .
VACUUM PUMP
REMOVAL
(1) Remove the front cover refer to front cover
(2) Remove 4 bol ts.
(3) Remove vacuum pump.
INSTALLATION
(1) To i nstal l the vacuum pump, al i gn the outer
part of the gear wi th the i nner part usi ng a screw-
dri ver or si mi l ar tool , al i gn wi th ti mi ng marks on
gear set and i nstal l .
(2) I nstal l bol ts and ti ghten to 20 Nm (15 ft. l bs.).
(3) I nstal l front cover.
PISTONS AND CONNECTING ROD
REMOVAL
(2) Remove cyl i nder heads, refer to cyl i nder head
(3) Rai se vehi cl e on host.
(4) Remove oi l pan, refer to oi l pan removal i n thi s
secti on.
(5) Remove top carbon ri dge of cyl i nder bores wi th
a rel i abl e ri dge reamer before removi ng pi stons from
cyl i nder bl ock. Be sure to keep tops of pistons
Fig. 51 Oil Cooler
Fig. 52 Vacuum Pump
9 - 68 ENGINE NS/GS
matchi ng cyl i nder number.
(7) Remove connecti ng rod cap. Push each pi ston
and rod assembl y out of cyl i nder bore.
CAUTION: During piston and rod removal. DO NOT
rotate piston and connecting rod or damage to the
oil jets extending out into the cylinder bore will
occur (Fig. 56).
i ng rod.
PISTON PINREMOVAL
(1) Secure connecti ng rod i n a soft jawed vi ce.
(2) Remove 2 cl i ps securi ng pi ston pi n (Fi g. 57).
(3) Push pi ston pi n out of pi ston and connecti ng
rod.
Fig. 53 Vacuum Pump Parts
Fig. 54 Vacuum Pump Mounting Hole
Fig. 55 Timing Marks
Fig. 56 Oil Jets
NS/GS ENGINE 9 - 69
PISTON RINGREMOVAL
(1) I denti fi cati on (I D) mark on face of upper and
i ntermedi ate pi ston ri ngs must poi nt toward pi ston
crown.
(2) Usi ng a sui tabl e ri ng expander, remove upper
and i ntermedi ate pi ston ri ngs (Fi g. 58).
(3) Remove the upper oi l ri ng si de rai l , l ower oi l
ri ng si de rai l and then oi l ri ng expander from pi ston.
(4) Careful l y cl ean carbon from pi ston crowns,
ski rts and ri ng grooves ensuri ng the 4 oi l hol es i n
the oi l control ri ng groove are cl ear.
Top compressi on ri ng gap .25 to .50 mm (.0098 to
.0196 i n.). Second compressi on ri ng gap .25 to .35
mm (.0098 to .0137 i n.). Oi l control ri ng gap .25 to
.58 mm (.0098 to .0228 i n.).
(2) I f ri ng gaps exceed di mensi on gi ven, new ri ngs
or cyl i nder l i ners must be fi tted. Keep pi ston ri ngs i n
pi ston sets.
Top compressi on ri ng gap .08 to .130 mm (.0031 to
.0051 i n.). Second compressi on ri ng gap .070 to .102
mm (.0027 to .0040 i n.). Oi l control ri ng gap .040 to
.072 mm (.0015 to .0028 i n.).
(1) I nstal l ri ngs on the pi stons usi ng a sui tabl e
ri ng expander (Fi g. 58).
(2) Top compressi on ri ng i s tapered and chromi um
pl ated. The second ri ng i s of the scraper type and
must be i nstal l ed wi th scrapi ng edge faci ng bottom of
the pi ston. The thi rd i s an oi l control ri ng (Fi g. 61).
Ri ng gaps must be posi ti oned, before i nserti ng pi ston
i nto the l i ners, as fol l ows (Fi g. 62).
(3) Top ri ng gap must be posi ti oned at 30 degrees
to the ri ght of the combusti on chamber recess (l ook-
i ng at the pi ston crown from above).
(4) Second pi ston ri ng gap shoul d be posi ti oned on
the opposi te si de of the combusti on chamber recess.
(5) Oi l control ri ng gap to be l ocated 30 degrees to
the l eft of combusti on chamber recess.
(6) When assembl i ng pi stons check that compo-
nents are i nstal l ed i n the same posi ti on as before di s-
Fig. 57 Piston Assembly
Fig. 58 Piston RingsRemoving and Installing
Fig. 59 Ring Gap Measurement
9 - 70 ENGINE NS/GS
assembl y, determi ned by the numbers stamped on
the crown of i ndi vi dual pi stons. Engi ne cyl i nders are
numbered starti ng from gear trai n end of the engi ne.
Face chamber recess side of piston towards
camshaft. Therefore, the numbers stamped on con
rod bi g end shoul d al so face i n the same di recti on. To
i nsert pi ston i nto cyl i nder, use a ri ng compressor as
shown i n (Fi g. 63).
PISTON PININSTALLATION
(1) Secure connecti ng rod i n soft jawed vi ce.
(2) Lubri cate pi ston pi n and pi ston wi th cl ean oi l .
(3) Posi ti on pi ston on connecti ng rod.
CAUTION: Ensure combustion recess in piston
crown and the bearing cap numbers on the con-
necting rod are on the same side.
(4) I nstal l pi ston pi n.
(5) I nstal l cl i ps i n pi ston to retai n pi ston pi n.
(6) Remove connecti ng rod from vi ce.
PISTONINSTALLATION
(1) Before i nstal l i ng pi stons, and connecti ng rod
oi l ri ng rai l gap (Fi g. 62).
and ti ghten wi th the speci al wrench (Fi g. 63).
Ensure position of rings does not change dur-
ing this operation.
Fig. 61 Piston Ring Identification
Fig. 62 Piston Ring Gap Location
Fig. 63 Installing Piston
NS/GS ENGINE 9 - 71
(4) Face chamber recess si de of pi ston towards
camshaft.
(5) I nstal l connecti ng rod bol t protectors on rod
bol ts.
rod and pi ston i nto cyl i nder bore and gui de rod over
the crankshaft journal .
CAUTION: During piston and rod installation. DO
NOT rotate piston and connecting rod or damage to
the oil jets extending out into the cylinder bore will
occur (Fig. 56).
(8) I nstal l rod caps. I nstal l nuts on cl eaned and
oi l ed rod bol ts and ti ghten nuts to 29.5 Nm (22 ft.
l b.) pl us 60.
CYLINDER LINER
REMOVAL
(1) Remove cyl i nder heads (refer to cyl i nder head
removal i n thi s secti on).
(2) Remove Oi l pan (refer to oi l pan removal i n
thi s secti on).
(3) Remove pi stons (refer to pi ston removal i n thi s
secti on).
(4) Use tool VM-1001 to remove l i ners (Fi g. 64).
(5) Remove shi ms from cyl i nder l i ner or cyl i nder
bl ock recess. Keep shi ms wi th each cyl i nder l i ner.
INSTALLATION
(1) Careful l y cl ean resi dual sealer from l i ner and
crankcase, and degrease the crankcase where i t
comes i nto contact wi th the l i ners. Referri ng to (Fi g.
65), i nstal l the l i ners i n the crankcase as shown (A),
rotati ng them back and forth by 45 i n order to guar-
antee correct posi ti oni ng.
(2) Measure the l i ner recess rel ati ve to bl ock deck
wi th a di al i ndi cator mounted on a speci al tool
VM-1010 A. All the measurements must be taken
on camshaft side. Zero di al gauge on bl ock deck.
(3) Move di al gauge to cyl i nder l i ner record read-
i ng on di al gauge.
(4) Remove l i ner and speci al tool .
(5) Then sel ect the correct shi m thi ckness to gi ve
proper protrusi on (0.01 - 0.06 mm).
(6) Fi t the shi m and the O-ri ngs onto the l i ner.
(7) Lubri cate the l ower l i ner l ocati on i n the bl ock.
Appl y LOCTI TE 275 to the corner of the l i ner seat.
Appl y LOCTI TE 275 uni forml y to the upper part of
the l i ner at area.
(8) Fi t the l i ners i n the crankcase maki ng sure
that the shi m i s posi ti oned correctl y i n the seat. Lock
the l i ners i n posi ti on usi ng speci al tool (VM-1016)
and bol ts (Fi g. 66). Cl ean the resi dual LOCTI TE on
the upper surface of the bl ock deck.
(9) Recheck the l i ner protrusi on. I t shoul d be 0.01
- 0.06 mm.
NOTE: A period of six hours must elapse between
the liners being installed and engine start-up. If
engine assembly is not continued after liner instal-
lation, the liners need to be clamped for twelve
hours minimum.
(10) Refer to Cyl i nder Head Removal and I nstal l a-
ti on procedure i n thi s secti on. To measure pi ston pro-
trusi on for i nstal l ati on of proper head gasket
thi ckness.
CRANKSHAFTREMOVAL
Refer to CRANKSHAFT MAI N BEARI NG
REMOVAL i n thi s secti on.
REAR CRANKSHAFT OIL SEAL
REMOVAL
(1) Remove transmi ssi on. Refer to Group 21,
Transmi ssi on for removal procedure.
(2) Remove fl ywheel .
Fig. 64 Cylinder LinerRemoval
9 - 72 ENGINE NS/GS
NOTE: Inspect O-ring in flywheel (Fig. 67).
(3) Remove rear crankshaft oi l seal from retai ner
(Fi g. 68).
CAUTION: When removing seal from retainer take
care not to damage retainer.
INSTALLATION
(1) I nstal l crankshaft oi l seal .
CAUTION: Use NEW flywheel bolt for the following
procedure.
(2) I nstal l new O-ri ng on fl ywheel . I nstal l fl y-
wheel . The 6 fl ywheel bol ts must be ti ghtened as fol -
l ows:
a. Torque the 6 fl ywheel bol ts to 60 Nm (44 ft.
l bs.).
b. Loosen 2 of the 6 bol ts, 180 apart. Torque the 2
bol ts to 20 Nm (180 i n. l bs.). Then usi ng a torque
angl e gauge rotate the 2 bol ts 65 addi ti onal .
c. Loosen the next 2 bol ts, 180 apart and fol l ow
the same procedure.
d. Loosen the l ast 2 bol ts, 180 apart and fol l ow
the same procedure.
(3) I nstal l Transmi ssi on. Refer to procedure i n
Group 21, Transmi ssi on.
HYDRAULIC TAPPETS
DISASSEMBLE AND ASSEMBLE
(1) Pry out pl unger retai ner spri ng cl i p.
(2) Cl ean varni sh deposi ts from i nsi de of tappet
body above pl unger cap.
(3) I nvert tappet body and remove pl unger cap,
pl unger, check val ve, check val ve spri ng, check val ve
Fig. 65 Cylinder LinerInstallation
NS/GS ENGINE 9 - 73
retai ner and pl unger spri ng. Check val ve coul d be
fl at or bal l .
Assembl e tappets i n reverse order.
CYLINDER HEAD COVERS
Remove any ori gi nal seal er from the cover seal i ng
surface of the engi ne cyl i nder head.
Remove al l resi due from the seal i ng surface usi ng
a cl ean, dry cl oth.
ROCKER ARMS AND PUSH RODS
CLEANING
Cl ean al l the components (Fi g. 69) wi th cl eani ng
sol vent.
Use compressed ai r to bl ow out the oi l passages i n
the rocker arms and push rods.
INSPECTION
I nspect the pi vot surface area of each rocker arm.
Repl ace any that are scuffed, pi tted, cracked or
excessi vel y worn.
I nspect the val ve stem ti p contact surface of each
rocker arm and repl ace any rocker arm that i s deepl y
pi tted.
I nspect each push rod end for excessi ve wear and
repl ace as requi red. I f any push rod i s excessi vel y
worn because of l ack of oi l , repl ace i t and i nspect the
correspondi ng hydraul i c tappet for excessi ve wear.
I nspect the push rods for strai ghtness by rol l i ng
them on a fl at surface or by shi ni ng a l i ght between
the push rod and the fl at surface.
A wear pattern al ong the l ength of the push rod i s
not normal . I nspect the engi ne cyl i nder head for
obstructi on i f thi s condi ti on exi sts.
Fig. 66 Liner Clamp Location
Fig. 67 Flywheel
Fig. 68 Crankshaft Seal
9 - 74 ENGINE NS/GS
CYLINDER HEAD
CLEANING
Thoroughl y cl ean the engi ne cyl i nder head and cyl -
i nder bl ock mati ng surfaces. Cl ean the i ntake and
exhaust mani fol d and engi ne cyl i nder head mati ng
surfaces. Remove al l gasket materi al and carbon.
Check to ensure that no cool ant or forei gn materi al
has fal l en i nto the tappet bore area.
Remove the carbon deposi ts from the combusti on
chambers and top of the pi stons.
INSPECTION
Use a strai ghtedge and feel er gauge to check the
fl atness of the engi ne cyl i nder head and bl ock mati ng
surfaces (Fi g. 70).
Mi ni mum cyl i nder head thi ckness 89.95mm (3.541
i n.)
CAUTION: If only one cylinder head is found to be
distorted and requires machining, it will also be
necessary to machine the remaining cylinders
heads and end plates by a corresponding amount
to maintain correct cylinder alignment.
VALVE GUIDE HEIGHT
(1) Val ve Gui des hei ght requi rement.
(2) Measurement A (Fi g. 71): 13.50 - 14.00 mm.
VALVE STEM-TO-GUIDE CLEARANCE
MEASUREMENT
(1) Measure and record i nternal di ameter of val ve
gui des. Val ve gui de i nternal di ameter i s 8.0 to 8.015
mm (.3149 to .3155 i n.).
(2) Measure val ve stems and record di ameters.
I ntake val ve stem di ameter 7.94 to 7.96 mm (.3125 to
.3133 i n). Exhaust val ve stem di ameter 7.92 to 7.94
mm (.3118 to .31215 i n).
(3) Subtract di ameter of val ve stem from i nternal
di ameter of i ts respecti ve val ve gui de to obtai n val ve
stem cl earance i n val ve gui de. Cl earance of i nl et
val ve stem i n val ve gui de i s .040 to .075 mm (.0015
to .0029 i n). Cl earance of exhaust val ve stem i n val ve
gui de i s .060 to .095 mm (.0023 to .0037 i n).
(4) I f val ve stem cl earance i n val ve gui de exceeds
tol erances, new val ve gui des must be i nstal l ed.
TIMING GEAR COVER
Be sure mati ng surfaces of ti mi ng gear cover and
cyl i nder bl ock are cl ean and free from burrs.
Fig. 69 Rocker Arm Components
NS/GS ENGINE 9 - 75
VALVE CLEANING
Cl ean al l carbon deposi ts from the combusti on
chambers, val ve ports, val ve stems, val ve stem
gui des and heads.
Cl ean al l gri me and gasket materi al from the
engi ne cyl i nder head machi ned gasket surfaces.
INSPECTION
I nspect for cracks i n the combusti on chambers and
val ve ports.
I nspect for cracks on the exhaust seat.
I nspect for cracks i n the gasket surface at each
cool ant passage.
I nspect val ves for burned, cracked or warped
heads.
I nspect for scuffed or bent val ve stems.
Repl ace val ves di spl ayi ng any damage.
Check val ve spri ng hei ght. (Fi g. 72).
HYDRAULIC TAPPETS
(1) Cl ean al l tappet parts i n a sol vent that wi l l
remove al l varni sh and carbon.
(2) Repl ace tappets that are unfi t for further ser-
vi ce wi th new assembl i es.
(3) I f pl unger shows si gns of scori ng or wear,
i nstal l a new tappet assembl y. I f val ve i s pi tted, or
val ve seat on end of pl unger i s prevented from seat-
i ng, i nstal l a new tappet assembl y.
OIL PUMP
CLEANING
Wash al l parts i n a sui tabl e sol vent and i nspect
INSPECTION
(1) Before i nstal l i ng oi l pump check pump bore
depth i n bl ock (A) and pump body hei ght (B) (Fi g.
73). Di fference between A and B shoul d be
0.020-0.082 mm.
(2) Check cl earance between rotors (Fi g. 75).
PISTONS
(1) Pi ston Di ameter: Si ze Group A: 91.93-91.94mm
(3.6191-3.6196 i n.) Si ze Group B: 91.94-91.95mm
Fig. 72 Valve Spring Chart
Fig. 73 Oil Pump Bore Depth
Fig. 74 Oil Pump Inner and Outer Rotors
9 - 76 ENGINE NS/GS
(3.6196-3.6200 i n.). Maxi mum wear l i mi t .05mm
(.0019 i n.).
(2) Check pi ston pi n bores i n pi ston for roundness.
Make 3 checks at 120 i nterval s. Maxi mum out of
roundness .05mm (.0019i n.).
(3) The pi ston di ameter shoul d be measured
approxi matel y 15 mm (.590 i n.) up from the base.
(4) Ski rt wear shoul d not exceed 0.1 mm (.00039
i n.).
(5) The cl earance between the cyl i nder l i ner and
pi ston shoul d not exceed 0.25 mm (.0009 i n.).
(6) Make sure the wei ght of the pi stons does not
di ffer by more than 5 g.
CONNECTING ROD
(1) Assembl e beari ng shel l s and beari ng caps to
thei r respecti ve connecti ng rods ensuri ng that the
serrati ons on the cap and reference marks are
al i gned.
(2) Ti ghten beari ng cap bol ts to 29 Nm (21 ft. l bs.)
pl us 60.
(3) Check and record i nternal di ameter of crank
end of connecti ng rod.
Note: When changi ng connecti ng rods, al l four
must have the same wei ght and be stamped wi th the
same number. Replacement connecting rods will
only be supplied in sets of four.
(4) Connecti ng rods are suppl i ed i n sets of four
si nce they al l must be of the same wei ght category.
Max al l owabl e wei ght di fference i s 18 gr. NOTE: On
one si de of the bi g end of the con-rod there i s a two-
di gi t number whi ch refers to the wei ght category. On
the other si de of the bi g end there i s a four di gi t
number on both the rod and the cap. These numbers
must both face the camshaft as wel l as the recess on
the pi ston crown (Fi g. 76). Li ghtl y heat the pi ston i n
oven. I nsert pi ston pi n i n posi ti on and secure i t wi th
provi ded snap ri ngs. The Four digit numbers
marked on con rod big end and rod cap must
be on the same side as the camshaft (Fig. 76).
After havi ng coated threads wi th Mol yguard, ti ghten
con rod bol ts to 29 Nm (21 ft. l bs.) pl us 60.
PISTON PIN
(1) Measure the di ameter of pi ston pi n i n the cen-
ter and both ends (Fi g. 77).
(2) Pi ston pi n di ameter i s 29.990 to 29.996mm
(1.1807 to 1.1809 i n.).
CRANKSHAFT
CRANKSHAFT J OURNALS
(1) Usi ng a mi crometer, measure and record crank-
shaft connecti ng rod journal s, take readi ng of each
journal 120 apart. Crankshaft journal di ameter i s
53.84 to 53.955mm (2.1196 to 2.1242 i n.).
(2) Crankshaft journal s worn beyond l i mi ts or
show si gns of out of roundness must be reground or
repl aced. Mi ni mum reground di ameter i s 53.69mm
(2.1137 i n.).
BEARING-TO-J OURNAL CLEARANCE
Compare i nternal di ameters of connecti ng rod wi th
crankshaft journal di ameter. Maxi mum cl earance
between connecti ng rod and crankshaft journal s .022
to .076mm (.0008 to .0029 i n.) (Fi g. 78).
CRANKSHAFT MAIN BEARING
INSPECTION
(1) Fi t mai n beari ng carri ers together and torque
to 42 Nm (31 ft. l bs.)
(2) Check i nternal di ameter of beari ngs.
Fig. 75 Checking Rotor Clearance
Fig. 76 Connecting Rod Identification
NS/GS ENGINE 9 - 77
(3) I f i nternal di ameter of ori gi nal beari ng i s bei ng
checked and fi gures are not wi thi n speci fi cati ons,
new beari ngs must be used.
(4) Check crankshaft mai n beari ng journal s to
beari ng cl earances. Cl earances of mai n beari ngs i s
.03 to .088mm (.0011 to .0035 i n.).
OIL PAN
Remove al l gasket materi al from cyl i nder bl ock. Be
careful not gouge pan seal i ng surface.
CYLINDER LINER
INSPECTION
round and taper wi th dai l bore gauge. The cyl i nder
bore out-of-round i s 0.100 mm (.0039 i nch) maxi mum
and cyl i nder bore taper i s 0.100 mm (0.0039 i nch)
maxi mum. I f the cyl i nder wal l s are badl y scuffed or
scored, new l i ners shoul d be i nstal l ed and honed, and
new pi stons and ri ngs fi tted.
shoul d be 10 mm ( 3/8 i nch.) up from bottom of bore.
SPECIFICATIONS
2. 5L VM DIESEL
DESCRIPTION . . . . . . . . . . . SPECIFICATIONS
Type . . . . . . . . . . . . . . . . . . . . . . 425CLI EE (36B)
Number of Cyl i nder . . . . . . . . . . . . . . . . . . . . . . 4
Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 mm
Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 mm
Capaci ty . . . . . . . . . . . . . . . . . . . . . . . 2499.5 cm3
I njecti on Order . . . . . . . . . . . . . . . . . . . . . 1-3-4-2
Compressi on Rati o . . . . . . . . . . . . . . . 21:1 ( 0.5)
Crankshaft
Front J ournal Diameter . . . . . . . . . . . . . . . . . . . .
Nomi nal . . . . . . . . . . . . . . . . . 62.98563.000 mm
0.25 . . . . . . . . . . . . . . . . . . . . 62.73562.750 mm
0.125 . . . . . . . . . . . . . . . . . . . 62.86062.875 mm
Front Bearing Diameter . . . . . . . . . . . . . . . . . . . .
Nomi nal . . . . . . . . . . . . . . . . . 63.04363.088 mm
0.25 . . . . . . . . . . . . . . . . . . . . 62.79362.838 mm
0.125 . . . . . . . . . . . . . . . . . . . 62.91862.963 mm
Cl earance Between Journal and Beari ng:
0.0430.103 mm . . . . . . . . . . . . . . . . . . . . . . . . . .
Center J ournal Diameter . . . . . . . . . . . . . . . . . . .
Fig. 77 Piston, Connecting Rod and Pin
Fig. 78 Bearing Clearance
Fig. 79 Liner Inspection
9 - 78 ENGINE NS/GS
Nomi nal . . . . . . . . . . . . . . . . . 63.00563.020 mm
0.25 . . . . . . . . . . . . . . . . . . . . 62.75562.770 mm
0.125 . . . . . . . . . . . . . . . . . . . 62.88062.895 mm
Center Bearing Diameter . . . . . . . . . . . . . . . . . . .
Nomi nal . . . . . . . . . . . . . . . . . 63.05063.093 mm
0.25 . . . . . . . . . . . . . . . . . . . . 62.80062.843 mm
0.125 . . . . . . . . . . . . . . . . . . . 62.92562.968 mm
0.0300.088 mm . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear J ournal Diameter . . . . . . . . . . . . . . . . . . . . .
Nomi nal . . . . . . . . . . . . . . . . . 79.98080.000 mm
0.25 . . . . . . . . . . . . . . . . . . . . 79.73079.750 mm
0.125 . . . . . . . . . . . . . . . . . . . 79.85579.875 mm
Rear Bearing Diameter . . . . . . . . . . . . . . . . . . . . .
Nomi nal . . . . . . . . . . . . . . . . . 80.04580.070 mm
0.25 . . . . . . . . . . . . . . . . . . . . 79.79579.820 mm
0.125 . . . . . . . . . . . . . . . . . . . 79.92079.945 mm
0.0450.090 mm (Wear Li mi t: 0.200 mm) . . . . . . .
Connecting Rod J ournal . . . . . . . . . . . . . . . . . . . .
Nomi nal . . . . . . . . . . . . . . . . . 53.94053.955 mm
0.25 . . . . . . . . . . . . . . . . . . . . 53.69053.705 mm
0.125 . . . . . . . . . . . . . . . . . . . 53.81553.830 mm
Connecting Rod Bearing . . . . . . . . . . . . . . . . . . . .
Nomi nal . . . . . . . . . . . . . . . . . 53.97754.016 mm
0.25 . . . . . . . . . . . . . . . . . . . . 53.72753.766 mm
0.125 . . . . . . . . . . . . . . . . . . . 53.85253.891 mm
0.0220.076 mm (Wear Li mi t: 0.200 mm) . . . . . . .
Crankshaft End Play
End Pl ay . . . . . . . . . . . . . . . . . . . . . 0.080.21 mm
Adjustment . . . . . . . . . . . . . . . . . Thrust Washers
Thrust Washers Avai l abl e . . . . . . . . 2.312.36 mm
Main Bearing Carriers
Front . . . . . . . . . . . . . . . . . . . . 67.02567.050 mm
Center . . . . . . . . . . . . . . . . . . . 66.67066.690 mm
Rear . . . . . . . . . . . . . . . . . . . . 85.98586.005 mm
Liners
I nternal Di ameter . . . . . . . . . . 92.00092.010 mm
Protrusi on . . . . . . . . . . . . . . . . . . . . 0.010.06 mm
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . Shi ms
Avai l abl e Shi ms: . . . . . . . . . . . . . . . . . . . 0.15 mm
Cylinder Head
Mi ni mum Thi ckness . . . . . . . . . . 89.9590.05 mm
Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steel
Gasket thi ckness: . . . . . . . 1.42 0.1 mm 0 Hol es
End Plates
Hei ght . . . . . . . . . . . . . . . . . . . . . 89.0290.00 mm
Connecting Rods
Wei ght (Wi thout the crank
beari ng) . . . . . . . . . . . . . . . . . . 11291195 grams
Smal l End Beari ng I nternal Di ameter
Mi ni mum . . . . . . . . . . . . . . . . . . . . . . . 30.035 mm
Maxi mum . . . . . . . . . . . . . . . . . . . . . . 30.050 mm
Crankshaft Beari ngs Standard I nternal
Di ameter . . . . . . . . . . . . . . . . . 53.99754.016 mm
Pistons
Ski rt Di ameter . . . . . . . . . . . . 91.93591.945 mm
(Measured at approxi matel y 15 mm above the
bottom of the ski rt)
Pi ston Cl earance . . . . . . . . . . . . . 0.0550.075 mm
Top of Pi ston to Cyl i nder Head . . . . 0.800.89 mm
Pi ston Protrusi on . . . . . 0.530.62 mm Fi t Gasket
(1.42), 0 Hol es
(1.62), 1 Hol e
(1.52), 2 Hol es
Piston Pins
Type . . . . . . . . . . . . . . . . . . . . . . . . . Ful l Fl oati ng
Pi n Di ameter . . . . . . . . . . . . . . 29.99029.996 mm
Cl earance . . . . . . . . . . . . . . . . . . 0.0040.014 mm
Piston Rings (Clearance in Groove)
Top . . . . . . . . . . . . . . . . . . . . . . . 0.0800.130 mm
Second . . . . . . . . . . . . . . . . . . . . . 0.0700.102 mm
Oi l Control . . . . . . . . . . . . . . . . . 0.0400.072 mm
Piston Rings (Fitted Gap)
Top . . . . . . . . . . . . . . . . . . . . . . . . . 0.250.50 mm
Second . . . . . . . . . . . . . . . . . . . . . . 0.200.35 mm
Oi l Control . . . . . . . . . . . . . . . . . . . 0.250.58 mm
Camshaft
Journal Di ameter Front . . . . . 53.46053.480 mm
Beari ng Cl earance . . . . . . . . . . . . . 0.060.13 mm
Journal Di ameter Center . . . . 53.46053.480 mm
Journal Di ameter Rear . . . . . . 53.46053.480 mm
Tappets
Outsi de Di ameter . . . . . . . . . . 22.19522.212 mm
Rocker Gear
Shaft Di ameter . . . . . . . . . . . . . 21.97922.00 mm
Bushi ng i nternal di ameter . . . 22.02022.041 mm
Assembl y Cl earance . . . . . . . . . . 0.0200.062 mm
Valves (Intake)
Opens . . . . . . . . . . . . . . . . . . . . . . . . 26 B.T.D.C.
Cl oses . . . . . . . . . . . . . . . . . . . . . . . . 58 A.B.D.C.
Valves (Exhaust)
Opens . . . . . . . . . . . . . . . . . . . . . . . . 64 B.B.D.C.
Cl oses . . . . . . . . . . . . . . . . . . . . . . . . 38 A.T.D.C.
NS/GS ENGINE 9 - 79
Valve FaceAngle
I ntake . . . . . . . . . . . . . . . . . . . . . . . 5530 5550
Exhaust . . . . . . . . . . . . . . . . . . . . . 4525 4535
Valve Head Diameter
I ntake . . . . . . . . . . . . . . . . . . . . . 40.0540.25 mm
Exhaust . . . . . . . . . . . . . . . . . . . . . 33.834.0 mm
Valve Head Stand Down
I ntake . . . . . . . . . . . . . . . . . . . . . . . 1.081.34 mm
Exhaust . . . . . . . . . . . . . . . . . . . . . 1.991.25 mm
Valve StemDiameter
I ntake . . . . . . . . . . . . . . . . . . . . . 7.9407.960 mm
Exhaust . . . . . . . . . . . . . . . . . . . . 7.9227.940 mm
Valve Clearance in Guide
I ntake . . . . . . . . . . . . . . . . . . . . . 0.0400.075 mm
Exhaust . . . . . . . . . . . . . . . . . . . . 0.0600.093 mm
Valve Guide
I nsi de Di ameter . . . . . . . . . . . . . . . 8.08.015 mm
Fi tted Hei ght . . . . . . . . . . . . . . . . . 13.514.0 mm
Valve Spring
Free Length . . . . . . . . . . . . . . . . . . . . . 44.65 mm
Fi tted Length . . . . . . . . . . . . . . . . . . . . . 38.6 mm
Load at Fi tted Length . . . . . . . . . . . . 34 6% Kg
Load at Top of Li ft . . . . . . . . . . . . . 92.5 4% Kg
Number of Coi l s . . . . . . . . . . . . 5.33 Val ve Ti mi ng
Oil Pressure
at 4000 rpm . . . . . 3.0 to 4.5 bar (Oi l at 90100C)
Pressure Rel i ef Val ve Opens . . . . . . . . . . 6.38 bar
Pressure Rel i ef Val veFree Length . . . . . 57.5 mm
Oil Pump
Outer Rotor End Fl oat . . . . . . . . . . 0.030.09 mm
I nner Rotor End Fl oat . . . . . . . . . . 0.030.09 mm
Outer Rotor to Body Di ameter
Cl earance . . . . . . . . . . . . . . . . . . 0.1300.230 mm
Rotor Body to Dri ve Gear Cl earance (Pump Not
Fi tted) . . . . . . . . . . . . . . . . . . . . . . 3.273.73 mm
TORQUE
Generator Mounting Bracket
Bol ts . . . . . . . . . . . . . . . . . . . . 47 Nm (35 ft. l bs.)
Camshaft Thrust Plate Retaining Bolts
Bol t . . . . . . . . . . . . . . . . . . . . . 24 Nm (18 ft. l bs.)
Cylinder Head
Bol ts . . See Cyl i nder Head I nstal l ati on Procedure
Connecting Rod
Bol ts . . . . . . . . . . . 29.5 Nm +60 (22 ft. l bs. +60)
Crankshaft Bearing Carrier
Bol ts . . . . . . . . . . . . . . . . . . . . 44 Nm (32 ft. l bs.)
Crankshaft damper (Pulley)
Nut . . . . . . . . . . . . . . . . . . . 441 Nm (325 ft. l bs.)
EGR Valve to Intake Manifold
Tube . . . . . . . . . . . . . . . . . . . . 26 Nm (19 ft. l bs.)
EGR Tube to EGR Valve
Bol ts . . . . . . . . . . . . . . . . . . . . 26 Nm (19 ft. l bs.)
Engine MountFront
Support Bracket Engi ne Bol ts . 68 Nm (50 ft. l bs.)
Support Bracket Transmi ssi on
Bol ts . . . . . . . . . . . . . . . . . . . 101 Nm (75 ft. l bs.)
Support Cushi on Crossmember
Bol ts . . . . . . . . . . . . . . . . . . . . 54 Nm (40 ft. l bs.)
Support Cushi on Thru Bol t . . . 65 Nm (48 ft. l bs.)
Engine MountRear
Support Bracket Transmi ssi on
Bol ts . . . . . . . . . . . . . . . . . . . 101 Nm (75 ft. l bs.)
Support Bracket to Engi ne
Bracket . . . . . . . . . . . . . . . . . 101 Nm (75 ft. l bs.)
Engine MountLeft
Transmi ssi on Mounti ng Bol ts . 54 Nm (40 ft. l bs.)
Engine MountRight
Mount to Frame Rai l Bol ts . . . 68 Nm (50 ft. l bs.)
Mount Bol t (Hori zontal ) . . . 145 Nm (107 ft. l bs.)
Mount Bol t (Verti cal ) . . . . . . . 101 Nm (75 ft. l bs.)
Right Engine Mount Bracket
Bol ts . . . . . . . . . . . . . . . . . . . . 40 Nm (30 ft. l bs.)
Exhaust Pipe to Turbocharger
Bol ts . . . . . . . . . . . . . . . . . . . 28 Nm (250 i n. l bs.)
Exhaust Manifold Outlet to Turbo
Nuts . . . . . . . . . . . . . . . . . . . . 32 Nm (24 ft. l bs.)
Exhaust Elbow to Turbo
Bol ts . . . . . . . . . . . . . . . . . . . . 30 Nm (22 ft. l bs.)
Exhaust Manifold Mounting
Nuts . . . . . . . . . . . . . . . . . . . . 30 Nm (22 ft. l bs.)
Flywheel
Bol ts . . . . . See Rear Crankshaft Seal I nstal l ati on
Procedure
EngineAdaptor Plate
Bol ts . . . . . . . . . . . . . . . . . . . . 47 Nm (35 ft. l bs.)
Front Timing Gear Cover
Bol ts . . . . . . . . . . . . . . . . . . . . 11 Nm (96 i n. l bs.)
Fuel Filter
Nuts . . . . . . . . . . . . . . . . . . . 28 Nm (250 i n. l bs.)
Glow Plugs
Pl ugs . . . . . . . . . . . . . . . . . . 14 Nm (120 i n. l bs.)
Idler Pulley Pump Support Bracket
Nuts . . . . . . . . . . . . . . . . . . . 26 Nm (228 i n. l bs.)
Idler Pulleys (left handed threads)
Bol ts . . . . . . . . . . . . . . . . . . . . 47 Nm (35 ft. l bs.)
Injector Pump fuel lines
Nuts . . . . . . . . . . . . . . . . . . 17.6 Nm (156 i n. l bs.)
Injector Pump Gear
Lock Nut . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Nm
Injector Pump Mounting
Nuts . . . . . . . . . . . . . . . . . . 27.5 Nm (240 i n. l bs.)
9 - 80 ENGINE NS/GS
Injector
Ti ghten to . . . . . . . . . . . . . . . . 65 Nm (48 ft. l bs.)
Intake Manifold Mounting
Nuts . . . . . . . . . . . . . . . . . . . 30 Nm (264 i n. l bs.)
Main Bearing Oil Delivery Union
Bol ts . . . . . . . . . . . . . . . . . . . . 54 Nm (40 ft. l bs.)
Oil Feed Line To Rocker Arms
Bol ts . . . . . . . . . . . . . . . . . 12.7 Nm (108 i n. l bs.)
Oil Feed Line to Block
Bol ts . . . . . . . . . . . . . . . . . 12.7 Nm (108 i n. l bs.)
Oil Feel Line to VacuumPump
Bol ts . . . . . . . . . . . . . . . . . 16.7 Nm (145 i n. l bs.)
Oil Filter
Ti ghten to . . . . . . . . . . . . . . . 9.8 Nm (85 i n. l bs.)
Oil Filter Adaptor
Oil Filter Base
Oil Pan Mounting
Bol ts . . . . . . . . . . . . . . . . . . . 12 Nm (108 i n. l bs.)
Oil Pickup Tube
Bol ts . . . . . . . . . . . . . . . . . . 11.3 Nm (100 i n. l bs.)
Oil Pump Mounting
Bol ts . . . . . . . . . . . . . . . . . 27.5 Nm (240 i n. l bs.)
Oil Pan Drain
Pl ug . . . . . . . . . . . . . . . . . . . . . 54 Nm (40 ft. l bs.)
Power Steering Pressure Hose
Fastener . . . . . . . . . . . . . . . . 28 Nm (240 i n. l bs.)
Power Steering Pulley
Nut . . . . . . . . . . . . . . . . . . . 170 Nm (125 ft. l bs.)
Rear Crankshaft Bearing Carrier
Bol ts . . . . . . . . . . . . . . . . . . 10.8 Nm (95 i n. l bs.)
Rocker ArmCover
Bol ts . . . . . . . . . . . . . . . . . 14.7 Nm (132 i n. l bs.)
Rocker ArmMounting
Nuts . . . . . . . . . . . . . . . . . . 29.4 Nm (264 i n. l bs.)
Power Steering Pump Mounting
Nuts . . . . . . . . . . . . . . . . . . 24.5 Nm (216 i n. l bs.)
Turbocharger Mounting
Nuts . . . . . . . . . . . . . . . . . . . 32 Nm (288 i n. l bs.)
Turbocharger Oil Delivery
Bol t . . . . . . . . . . . . . . . . . . 27.5 Nm (240 i n. l bs.)
Turbocharger Oil Drain
Bol ts . . . . . . . . . . . . . . . . . . 10.8 Nm (95 i n. l bs.)
VacuumPump Mounting
Bol ts . . . . . . . . . . . . . . . . . . 10.8 Nm (95 i n. l bs.)
Water Manifold Mounting
Bol ts . . . . . . . . . . . . . . . . . . 11.8 Nm (108 i n. l bs.)
Water Pump Pulley
Bol ts . . . . . . . . . . . . . . . . . 27.5 Nm (240 i n. l bs.)
SPECIAL TOOLS
2. 5L VM DIESEL
Crankshaft Pulley and Gear Remover VM.1000A
Cylinder Liner Puller VM.1001
Crankshaft Bearing Remover/Installer VM.1002
NS/GS ENGINE 9 - 81
Crankshaft Remover/Installer Sleeve VM.1004
Torque Angle Gauge VM.1005
Cylinder Head Bolt Wrench VM.1006A
Cylinder Head Guide Studs VM.1009
Cylinder Liner Protrusion Tool VM.1010
Injector Socket Remover/Installer VM.1012A
9 - 82 ENGINE NS/GS
Dial Indicator Gauge VM.1013
Flywheel Locking Tool VM.1014
Timing Cover Oil Seal Installer VM.1015
Cylinder Retainers VM.1016
Cylinder Head Bolt Wrench M12 VM.1018
NS/GS ENGINE 9 - 83
Adapter Cylinder Leakage Tester VM.1021
Cylinder Head Bolt Wrench M14 VM.1019
Support Brackets Engine Removal/Installation
VM.1026
9 - 84 ENGINE NS/GS
EXHAUST SYSTEM AND INTAKE MANIFOLD
CONTENTS
page page
GENERAL INFORMATION
CATALYTIC CONVERTERS . . . . . . . . . . . . . . . . . 1
EXHAUST FLEX-J OINT COUPLING . . . . . . . . . . . 2
EXHAUST GAS RECIRCULATION (EGR) . . . . . . . 2
EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 1
HEAT SHIELDS . . . . . . . . . . . . . . . . . . . . . . . . . . 2
INTAKE/EXHAUST MANIFOLD2.4L ENGINE . . 3
INTAKE/EXHAUST MANIFOLD3.0L ENGINE . . 3
INTAKE/EXHAUST MANIFOLD3.3/3.8L
ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 3
EXHAUST MANIFOLD2.4L ENGINE . . . . . . . . 8
EXHAUST MANIFOLD3.0L ENGINE . . . . . . . 11
EXHAUST MANIFOLDS3.3/3.8L ENGINE . . . 16
EXHAUST PIPES, MUFFLERS AND TAILPIPES . 4
INTAKE MANIFOLD LOWER2.4L ENGINE . . . . 6
INTAKE MANIFOLD3.0L ENGINE . . . . . . . . . . 8
INTAKE MANIFOLD3.3/3.8L ENGINE . . . . . . 12
UPPER INTAKE MANIFOLD2.4L ENGINE . . . . 4
EXHAUST MANIFOLD . . . . . . . . . . . . . . . . . . . . 17
INTAKE MANIFOLD . . . . . . . . . . . . . . . . . . . . . . 17
SPECIFICATIONS
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . 18
GENERAL INFORMATION
EXHAUST SYSTEM
The exhaust systems are produced i n several con-
fi gurati ons, dependi ng on engi ne and vehi cl e (Fi g. 1).
AWD vehi cl es have a catal yti c converter mounted
heat shi el d. The tai l pi pes, muffl ers, and resonators
are tuned to each vehi cl e/powertrai n combi nati on.
CATALYTIC CONVERTERS
There i s no regul arl y schedul ed mai ntenance on
any Chrysl er catal yti c converter. I f damaged, the con-
verter must be repl aced.
CAUTION: Due to exterior physical similarities of
some catalytic converters with pipe assemblies,
extreme care should be taken with replacement
parts. There are internal converter differences
required in some parts of the country.
The combusti on reacti on caused by the catal yst
rel eases addi ti onal heat i n the exhaust system. Caus-
i ng temperature i ncreases i n the area of the reactor
under severe operati ng condi ti ons. Such condi ti ons
can exi st when the engi ne mi sfi res or otherwi se does
not operate at peak effi ci ency. Do not remove spark
pl ug wi res from pl ugs or by any other means short
out cyl i nders of the exhaust system i f equi pped wi th
Fig. 1 Exhaust SystemTypical (All Vehicles)
NS EXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 1
a catal yti c converter. Fai l ure of the catal yti c con-
verter can occur due to temperature i ncreases caused
by unburned fuel i gni ti ng when passi ng through the
converter.
The use of the catal ysts al so i nvol ves some non-au-
tomoti ve probl ems. Unl eaded gasol i ne must be used
to avoi d poi soni ng the catal yst core. Do not al l ow
engi ne to operate at fast i dl e for extended peri ods
(over 5 mi nutes). Thi s condi ti on may resul t i n exces-
si ve exhaust system and fl oor pan temperatures.
EXHAUST GAS RECIRCULATION (EGR)
To assi st i n the control of oxi des of ni trogen (NOx)
i n engi ne exhaust, al l engi nes are equi pped wi th an
exhaust gas reci rcul ati on system. The use of exhaust
gas to di l ute i ncomi ng ai r/fuel mi xtures l owers peak
fl ame temperatures duri ng combusti on, thus l i mi ti ng
the formati on of NOx.
Exhaust gases are taken from openi ng i n the
exhaust mani fol d passage to the i ntake mani fol d.
REFER TO SECTI ON 25 FOR A COMPLETE
DESCRI PTI ON, DI AGNOSI S AND SERVI CE PRO-
CEDURES ON THE EXHAUST GAS RECI RCULA-
TI ON SYSTEM AND COMPONENTS.
HEAT SHIELDS
Heat shi el ds (Fi g. 2) are needed to protect both the
vehi cl e and the fl oor pan from the hi gh temperatures
devel oped near the catal yti c converter and muffl er.
Avoid application of rust prevention com-
pounds or undercoating materials to exhaust
system floor pan heat shields on cars so
equipped. Light over spray near the edges is
permitted. Application of coating will greatly
reduce the efficiency of the heat shields result-
ing in excessive floor pan temperatures and
objectionable fumes.
EXHAUST FLEX-JOINT COUPLING
A exhaust fl ex-joi nt coupl i ng (Fi g. 3) i s used to
secure the catal yti c converter to the engi ne mani fol d.
Thi s l i vi ng joi nt actual l y moves back and forth as the
engi ne moves, preventi ng breakage that coul d occur
from the back-and-forth moti on of a transverse
mounted engi ne.
The exhaust fl ex-joi nt has four bol ts, four fl ag nuts
and a gasket that are separate parts from the
exhaust fl ex-joi nt. The fl ex-joi nt i s wel ded to the cat-
al yti c converter.
Fig. 2 Heat Shields
Fig. 3 Flex-Joint
11 - 2 EXHAUST SYSTEM AND INTAKE MANIFOLD NS
CAUTION: When servicing, care must be exercised
not to dent or bend the bellows of the flex-joint.
Should this occur, the flex-joint will eventually fail
and require the catalytic converter be replaced.
INTAKE/EXHAUST MANIFOLD 2. 4L ENGINE
The i ntake mani fol d i s a tuned two-pi ece al umi -
num casti ng wi th i ndi vi dual pri mary runners l eadi ng
from a pl enum to the cyl i nders. The mani fol d i s
desi gned to boost torque whi ch i s desi red for excel -
l ent engi ne response and usabl e power output.
The exhaust mani fol d i s made of nodul ar cast i ron
for strength and hi gh temperatures.
INTAKE/EXHAUST MANIFOLD 3. 0L ENGINE
The al umi num al l oy mani fol d i s a cross type wi th
l ong runners to i mprove ai r fl ow. The runners,
attachi ng bel ow at the cyl i nder head, al so attach
above and support an ai r pl enum. The ai r pl enum
chamber absorbs ai r pul sati ons created duri ng the
sucti on phase of each cyl i nder.
Both exhaust mani fol ds are a l og styl e made of
ducti l e cast i ron. Exhaust gasses, col l ected from the
front cyl i nder bank, l eave the front mani fol d through
an end outl et and are fed through an upper crossover
tube to the rear mani fol d. The col l ected exhaust from
both mani fol ds are combi ned at the exhaust outl et, to
the exhaust pi pe.
INTAKE/EXHAUST MANIFOLD 3. 3/3. 8L ENGINES
The i ntake mani fol d i s a tuned two-pi ece semi -per-
manent mol d al umi num casti ng wi th i ndi vi dual pri -
mary runners l eadi ng from a pl enum to the
cyl i nders. The mani fol d i s desi gned to boost torque i n
the 3600 rpm range and contri butes to the engi nes
broad, fl at torque curve, whi ch was desi red for excel -
l ent engi ne tractabi l i ty, response and usabl e power
output.
The i ntake mani fol d i s al so cored wi th upper l evel
EGR passages for bal anced cyl i nder to cyl i nder EGR
di stri buti on.
The exhaust mani fol ds are l og type wi th a cross-
over and are attached di rectl y to the cyl i nder heads.
They are made from nodul ar cast i ron.
EXHAUST SYSTEM
EXCESSIVE EXHAUST
NOISE (UNDER HOOD)
1. Exhaust manifold cracked or broken. 1. Replace manifold.
2. Manifold to cylinder head leak. 2. Tighten manifold and/or replace gasket.
3. EGR Valve to manifold gasket leakage. 3. Tighten fasteners or replace gasket.
4. EGR Valve to EGR tube gasket
leakage.
4. Tighten fasteners or replace gasket.
5. EGR tube to manifold tube leakage. 5. Tighten tube nut.
6. Exhaust flex-joint to manifold leak. 6. Tighten joint fasteners and/or replace
gasket.
7. Exhaust flex-joint. 7. Replace catalytic converter assembly.
8. Pipe and shell noise from front exhaust
pipe.
8. Characteristic of single wall pipe.
EXCESSIVE EXHAUST
NOISE
1. Leak at exhaust pipe joints. 1. Tighten clamps at leaking joints.
2. Burned or rusted out muffler assembly
or exhaust pipe.
2. Replace muffler resonator tailpipe
assembly or exhaust pipe with catalytic
converter assembly.
3. Burned or rusted out resonator. 3. Replace muffler resonator tailpipe
assembly.
4. Restriction in exhaust system. 4. Remove restriction, if possible, or
replace as necessary.
5. Converter material in muffler. 5. Replace muffler and converter
assemblies. Check fuel injection and
ignition systems for proper operation.
EXHAUST PIPES, MUFFLERS AND TAILPIPES
REMOVAL
(1) Rai se vehi cl e on hoi st and appl y penetrati ng
oi l to cl amp bol ts and nuts of component bei ng
removed.
(2) Loosen cl amps and supports (Fi g. 5) and (Fi g.
4) from exhaust system to permi t al i gnment of parts
duri ng assembl y.
(3) When removi ng tai l pi pe, rai se rear of vehi cl e
to rel i eve body wei ght from rear spri ngs to provi de
cl earance between pi pe and rear axl e parts.
(4) Cl ean ends of pi pes or muffl er to assure mat-
i ng of al l parts. Di scard broken or worn i nsul ators,
rusted cl amps, supports and attachi ng parts. When
replacement is required on any component of
the exhaust system. It is important that origi-
nal equipment parts (or their equivalent) be
used;
To i nsure proper al i gnment wi th other parts i n
the system.
Provi de acceptabl e exhaust noi se l evel s and does
not change exhaust system back pressure that coul d
effect emi ssi ons and performance.
INSTALLATION
(1) Assembl e pi pes, muffl er support and cl amp
l oosel y to permi t al i gnment of al l parts.
(2) Begi nni ng at front of system, al i gn and cl amp
each component to mai ntai n posi ti on and proper
cl earance wi th underbody parts.
(3) Ti ghten the cl amp and support to the proper
torques and cl earances (Fi g. 4).
UPPER INTAKE MANIFOLD 2. 4L ENGINE
REMOVAL
(2) Di sconnect ai r i ntake tube and resonator box
from throttl e body and remove.
(3) Remove connector from throttl e posi ti on sensor
(Fi g. 6).
(4) Remove connector from i dl e ai r control motor
(Fi g. 6).
(5) Remove connector from MAP sensor (Fi g. 11).
Fig. 4 Exhaust System Components
Fig. 5 Band Clamp
(6) Remove vacuum l i nes for purge sol enoi d and
PCV val ve at i ntake mani fol d (Fi g. 7).
(7) Remove vacuum l i nes for power brake booster
and speed control vacuum reservoi r at upper i ntake
mani fol d fi tti ngs (Fi g. 8).
(8) Remove throttl e cabl e and speed control cabl e
(i f equi pped) from throttl e l ever (Fi g. 9).
(9) Remove throttl e cabl es from bracket by com-
pressi ng retai ni ng tabs.
(10) Remove two top bol ts from i ntake mani fol d to
rear support bracket and spacer (Fi g. 10).
(11) Remove upper bol t from i ntake mani fol d to
front support bracket (Fi g. 11).
(12) Remove di psti ck.
(13) Remove di psti ck tube.
CAUTION: Moving the dipstick tube will cause dam-
age to the sealer, causing an oil leak. Dipstick tube
must be sealed at cylinder block.
(14) Remove upper i ntake mani fol d bol ts. Remove
upper i ntake mani fol d.
CAUTION: Cover intake manifold to prevent foreign
material from entering engine.
Fig. 6 Throttle Body Electrical Connectors
Fig. 7 Vacuum Line Connections
Fig. 8 Vacuum Fitting at Rear of Upper Intake
Manifold
Fig. 9 Throttle Cable Attachment to Throttle Body
Fig. 10 Intake Manifold Rear Support Bracket
INSTALLATION
(1) I nstal l new upper i ntake mani fol d gasket.
NOTE: Center outboard fastener is a double stud.
(2) Ti ghten upper i ntake mani fol d fasteners start-
i ng at center and progressi ng outward i n both di rec-
ti ons. Ti ghten bol ts to 28 Nm (250 i n. l bs.). Repeat
thi s procedures unti l al l fasteners are at speci fi ed
torque.
(3) I nstal l di psti ck tube. Seal tube to cyl i nder
bl ock usi ng Mopar Stud N Beari ng Mount Adhe-
si ve. Ti ghten di psti ck tube fastener to 12 Nm (105
i n. l bs.)
(4) I nstal l di psti ck.
(5) I nstal l upper bol t i n i ntake mani fol d to front
support bracket (Fi g. 11). Torque to 28 Nm (250 i n.
l bs.).
(6) I nstal l two top bol ts at i ntake mani fol d to rear
support bracket maki ng sure bracket to mani fol d
spacer i s i n pl ace (Fi g. 10). Ti ghten bol ts to 28 Nm
(250 i n. l bs.)
(7) I nstal l throttl e cabl es i n bracket.
(8) I nstal l throttl e cabl e and speed control cabl e (i f
equi pped) to throttl e l ever.
(9) I nstal l vacuum l i nes for power brake booster
and speed control vacuum reservoi r at upper i ntake
mani fol d fi tti ngs.
(10) I nstal l vacuum l i nes for purge sol enoi d and
PCV val ve.
(11) I nstal l el ectri cal connectors for MAP sensor,
throttl e posi ti on sensor, and i dl e ai r control motor.
(12) I nstal l ai r i ntake tube and resonator box to
throttl e body.
INTAKE MANIFOLD LOWER 2. 4L ENGINE
WARNING: RELEASE FUEL SYSTEM PRESSURE
BEFORE SERVICING FUEL SYSTEM COMPONENTS.
SERVICE VEHICLES IN WELL VENTILATED AREAS
AND AVOID IGNITION SOURCES. NEVER SMOKE
WHILE SERVICING THE VEHICLE
To rel ease fuel pressure, refer to the Fuel Del i very
System Pressure Rel ease secti on of Group 14 Fuel
REMOVAL
dure before attempting any repairs.
(2) Remove upper i ntake mani fol d. Refer to proce-
dure i n thi s secti on.
CAUTION: Cover intake manifold to prevent foreign
material from entering engine.
(3) Di sconnect el ectri cal connector from i ntake ai r
temperature sensor (Fi g. 12).
(4) Remove fuel hose qui ck connect fi tti ng from
the chassi s tube (Fi g. 13). Refer to Fuel Hoses,
Clamps and Quick Connect Fittings in the Fuel
Delivery Section of this Group.
WARNING: WRAP A SHOP TOWEL AROUND
HOSES TO CATCH ANY GASOLINE SPILLAGE.
Fig. 11 Intake Manifold Front Support Bracket and
Map Sensor
(5) Drai n cool i ng system. Refer to Group 7, Cool -
i ng System for procedure.
(6) Remove heater, and upper radi ator hoses at
i ntake mani fol d.
(7) Di sconnect cool ant temperature sensor (Fi g.
14).
(8) Remove the accessory dri ve bel t. Refer to
Accessory Dri ve bel t Removal and I nstal l ati on i n
Group 7, Cool i ng System for procedure.
(9) Remove fasteners attachi ng generator bracket
to cyl i nder head, and bl ock.
(10) Remove i ntake mani fol d center support
bracket bol ts (Y bracket) (Fi g. 15)
(11) Di sconnect fuel i njector harness.
(12) Remove l ower i ntake mani fol d fasteners (Fi g.
16). Remove the mani fol d from engi ne.
(13) I nspect and cl ean mani fol d. Refer to Cl eani ng
and I nspecti on outl i ned i n thi s secti on for proce-
dures.
INSTALLATION
If the following items were removed, install and
torque to:
Fuel Rai l Bol ts 22 Nm (200 i n. l bs.)
Engi ne Outl et Connector Bol ts 28 Nm (250 i n.
l bs.)
Cool ant Temperature Sensor 7 Nm (60 i n. l bs.)
I ntake Ai r Temperature Sensor 28 Nm (250 i n.
l bs.)
(1) Usi ng a new i ntake gasket, posi ti on i ntake
mani fol d on the engi ne and i nstal l retai ni ng bol ts.
Fig. 13 Fuel Line Quick Disconnect
Fig. 14 Coolant Temperature Sensor2.4L
Fig. 15 Intake Manifold Center Support Bracket
Fig. 16 Intake Manifold Fasteners
(2) Ti ghten i ntake mani fol d fasteners i n the fol -
l owi ng sequence (Fi g. 16). Torque to 23 Nm (200 i n.
l bs.). Repeat thi s procedure unti l al l bol ts are at
speci fi ed torque.
(3) I nstal l i ntake mani fol d center support bracket
bol ts (Y bracket):
Fastener to bl ock 54 Nm (40 ft. l bs.)
Fastener to i ntake 28 Nm (250 i n. l bs.)
(4) I nstal l fuel hose qui ck connector fi tti ng to
chassi s tubes. Refer to Fuel Hoses, Clamps and
Quick Connect Fittings in Group 14, Fuel Deliv-
ery. Push the fi tti ng onto the chassi s tube unti l i t
cl i cks i nto pl ace. Pul l on the fi tti ng to ensure com-
pl ete i nserti on.
(5) Reverse removal procedures 2 through 12 for
i nstal l ati on.
CAUTION: When using the ASD Fuel System Test,
the ASD relay and fuel pump relay remain energized
for 7 minutes or until the test is stopped, or until
the ignition switch is turned to the Off position.
(6) Wi th the i gni ti on key i n ON posi ti on, access
the DRB scan tool ASD Fuel System Test to pressur-
i ze the fuel system. Check for l eaks.
EXHAUST MANIFOLD 2. 4L ENGINE
REMOVAL
(1) Rai se vehi cl e and di sconnect exhaust pi pe from
the exhaust mani fol d at the fl ex-joi nt.
(2) Di sconnect Oxygen Sensor l ead wi re at the rear
exhaust mani fol d (Fi g. 17).
(3) Remove the bol ts attachi ng the mani fol d to the
cyl i nder head. Remove mani fol d (Fi g. 17).
dures.
INSTALLATION
(1) I nstal l exhaust mani fol d wi th a new gasket
and ti ghten attachi ng nuts i n the order shown i n
(Fi g. 17) to 20 Nm (175 i n. l bs.).
(2) Attach exhaust pi pe to exhaust mani fol d and
ti ghten bol t to 28 Nm (250 i n. l bs.).
(3) Connect heated oxygen sensor l ead (Fi g. 17).
INTAKE MANIFOLD 3. 0L ENGINE
REMOVAL
dure (before attempting any repairs). Refer to
Group 14 Fuel System for procedure.
i ng system. See Cool i ng System, Group 7.
(3) Remove ai r i nl et resonator to throttl e body
hose.
(4) Remove throttl e cabl e and transaxl e ki ckdown
l i nkage (Fi g. 18).
(5) Remove automati c i dl e speed (AI S) motor and
throttl e posi ti on sensor (TPS) wi ri ng connectors from
throttl e body (Fi g. 19).
(6) Remove vacuum hose harness from throttl e
body.
(7) Remove PCV and Brake booster hoses from
Ai r I ntake Pl enum.
(8) Remove I gni ti on Coi l from I ntake Pl enum
(Fi g. 20).
(9) Remove wi ri ng connectors from cool ant temper-
ature sensor (Fi g. 21).
(10) Remove vacuum connecti ons from Ai r I ntake
Pl enum vacuum connector.
(11) Remove fuel hose from fuel rai l (Fi g. 21).
WARNING: WRAP SHOP TOWELS AROUND HOSES
TO CATCH ANY GASOLINE SPILLAGE.
Fig. 17 Exhaust Manifold Attaching Points2.4L
Engine
Fig. 18 Throttle Cable Attachment
(12) Remove fasteners from Ai r I ntake Pl enum to
I ntake Mani fol d (Fi g. 22).
(13) Remove Ai r I ntake Pl enum (Fi g. 23).
(14) Cover i ntake mani fol d wi th sui tabl e cover
when servi ci ng (Fi g. 24).
(15) Di sconnect Fuel I njector wi ri ng harness from
engi ne wi ri ng harness.
Fig. 19 Electrical and Vacuum Connections to
Throttle Body
Fig. 21 Coolant Temperature Sensor Electrical
Connections
Fig. 22 Air Intake Plenum to Intake Manifold
Attaching Bolts
Fig. 23 Removing Air Intake Plenum
Fig. 24 Vacuum Connections for Fuel Rail and Fuel
Pressure Regulator
(16) Remove fuel rai l attachi ng bol ts and l i ft fuel
rai l assembl y from i ntake mani fol d.
(17) Separate radi ator hose from thermostat hous-
i ng and heater hose from heater pi pe.
(18) Remove nut and washer assembl i es and
remove i ntake mani fol d (Fi g. 25).
dures.
INSTALLATION
(1) Posi ti on new i ntake mani fol d gaskets on cyl i n-
der head and i nstal l i ntake (cross) mani fol d.
(2) I nstal l nuts and washers and ti ghten i n sev-
eral steps i n order shown i n (Fi g. 26) to 20 Nm (174
i n. l bs.).
(3) Make sure the i njector hol es are cl ean and al l
pl ugs have been removed.
(4) Lube i njector O-ri ng wi th a drop of cl ean
engi ne oi l to ease i nstal l ati on.
(5) Put the ti p of each i njector i nto thei r ports.
Push the assembl y i nto pl ace unti l the i njectors are
seated i n the ports.
(6) I nstal l the fuel rai l attachi ng bol ts and torque
to 13 Nm (115 i n. l bs.).
(7) I nstal l fuel suppl y and the vacuum crossover
tube hol d-down bol t and torque to 10 Nm (95 i n.
l bs.).
(8) Remove coveri ng from l ower i ntake mani fol d
and cl ean surface.
(9) Pl ace i ntake mani fol d gaskets with beaded
sealant side up on l ower mani fol d. Put ai r i ntake i n
pl ace. I nstal l attachi ng fasteners and ti ghten i n sev-
eral steps i n sequence shown (Fi g. 27) to 13 Nm (115
i n. l bs.).
Fig. 25 Intake and Exhaust Manifolds 3.0L Engine
Fig. 26 Fastener Tightening Sequence for Intake
(Cross) Manifold
(10) Connect fuel l i ne to fuel rai l (Fi g. 21). Torque
hose cl amps to 1 Nm (10 i n. l bs.).
(11) Connect vacuum harness to ai r i ntake pl e-
num.
(12) Connect and cool ant temperature sensor el ec-
tri cal connector to sensor (Fi g. 21).
(13) Connect PCV and brake booster suppl y hose
to i ntake pl enum.
(14) Connect automati c i dl e speed (AI S) motor
and throttl e posi ti on sensor (TPS) el ectri cal connec-
tors (Fi g. 19).
(15) Connect vacuum vapor harness to throttl e
body (Fi g. 19).
(16) I nstal l throttl e cabl e and transaxl e ki ckdown
l i nkage (Fi g. 18).
(17) I nstal l ai r i nl et resonator hose assembl y to
throttl e body.
(18) I nstal l radi ator to thermostat housi ng hose
and heater hose to heater pi pe ni ppl e.
(19) Fi l l cool i ng system. Refer to Fi l l i ng the Cool -
i ng System outl i ned i n Group 7 Cool i ng System for
procedure.
(21) Wi th the DRB Scan Tool use ASD Fuel Sys-
tem Test to pressuri ze system to check for l eaks.
The Auto Shutdown (ASD) Relay will remain ener-
gized for 7 minutes or until the ignition switch is
turned to the OFF position, or Stop All Test is
selected.
EXHAUST MANIFOLD 3. 0L ENGINE
REMOVAL
(1) Rai se vehi cl e and di sconnect exhaust pi pe
from rear (cowl si de) exhaust mani fol d at the fl ex-
joi nt.
(2) Di sconnect Oxygen Sensor l ead wi re at the
rear exhaust mani fol d (Fi g. 28).
(3) Remove bol ts attachi ng cross-over pi pe to
mani fol d (Fi g. 30).
(4) Remove rear heat shi el d (Fi g. 29).
(5) Remove nuts attachi ng rear mani fol d to cyl i n-
der head and remove mani fol d.
(6) Lower vehi cl e and remove screws attachi ng
front heat shi el d to front mani fol d (Fi g. 31).
(7) Remove bol ts fasteni ng crossover pi pe to front
exhaust mani fol d and nuts fasteni ng mani fol d to cyl -
i nder head. Remove assembl i es.
(8) I nspect and cl ean mani fol ds. Refer to Cl eani ng
dures.
INSTALLATION
I nstal l the gaskets wi th the numbers 1-3-5
embossed on the top on the rear bank and those wi th
numbers 2-4-6 on the front (Radi ator si de) bank (Fi g.
32).
(1) I nstal l rear exhaust mani fol d and ti ghten
attachi ng nuts to 20 Nm (175 i n. l bs.).
Fig. 27 Intake Plenum Tightening Sequence
Fig. 28 Disconnect Up Stream Heated Oxygen
Sensor Connection
Fig. 29 Rear Exhaust Manifold Heat Shield
(2) Attach exhaust pi pe to exhaust mani fol d and
ti ghten bol ts to 28 Nm (250 i n. l bs.)
(3) Attach crossover pi pe to exhaust mani fol d and
ti ghten bol t to 69 Nm (51 ft. l bs.)
(4) I nstal l rear exhaust mani fol d heat shi el d (Fi g.
29).
(5) Connect heated oxygen sensor l ead (Fi g. 28).
(6) I nstal l front exhaust mani fol d and attach
exhaust crossover.
(7) I nstal l front exhaust mani fol d heat shi el d and
ti ghten attachi ng screws to 15 Nm (130 i n. l bs.) (Fi g.
31).
INTAKE MANIFOLD 3. 3/3. 8L ENGINE
REMOVAL
(1) Remove wi ndshi el d wi per modul e. Refer to
Group 8K Wi ndshi el d Wi per and Washer Systems for
procedure.
dure (before attempting any repairs). Refer to
Group 14 Fuel System for procedure.
(3) Drai n cool i ng system. See Cool i ng System,
(4) Remove ai r i nl et resonator to throttl e body
hose assembl y.
(5) Remove throttl e cabl e. Refer to Group 14 Fuel
Systems for procedure. Remove wi ri ng harness from
throttl e cabl e bracket.
(6) Remove automati c i dl e speed (AI S) motor and
throttl e posi ti on sensor (TPS) wi ri ng connectors from
(7) Remove EGR transducer connector.
body (Fi g. 33).
(9) Remove PCV and brake booster hoses from ai r
i ntake pl enum.
Fig. 30 Crossover Pipe
Fig. 31 Front Exhaust Manifold Heat Shield
Fig. 32 Identify Exhaust Manifold Gaskets
Fig. 33 Electrical and Vacuum Connection to
Throttle Body
(10) Di sconnect MAP Sensor el ectri cal connecti on
(Fi g. 34).
(11) Remove EGR tube fl ange from i ntake pl e-
num.
(12) Remove vacuum harness connectors from
i ntake pl enum (Fi g. 34).
(13) Remove cyl i nder head to i ntake pl enum strut
(Fi g. 35)
(14) Remove the engi ne mounted ground strap.
(15) Remove the fuel hose qui ck connect fi tti ng
from the fuel l i ne by usi ng an open end wrench push-
i ng i n on the pl asti c ri ng l ocated on the end of the
fi tti ngs. Gentl y pul l the fi tti ng from the fuel l i ne
(Fi g. 36).
HOSES TO CATCH ANY GASOLINE SPILLAGE DUR-
ING REMOVAL.
(16) Remove di rect i gni ti on system (DI S) coi l s and
generator bracket to i ntake mani fol d bol t (Fi g. 37).
(17) Remove bol ts from generator to i ntake mani -
fol d bracket. Loosen top generator mounti ng bol t,
and move bracket up so i ntake mani fol d can cl ear
mounti ng studs (Fi g. 38).
(18) Remove i ntake mani fol d bol ts and remove the
(20) Remove fuel tube retai ner bracket screw and
fuel rai l attachi ng bol ts (Fi g. 39). Spread the retai ner
bracket to al l ow fuel tube removal cl earance.
(21) Di sconnect cam sensor and cool ant tempera-
ture sensor (Fi g. 40).
(22) Remove fuel i njector wi ri ng cl i p from i ntake
mani fol d water tube.
(23) Remove fuel rai l . Be careful not to damage
the rubber i njector O-ri ngs upon removal from thei r
ports (Fi g. 41).
(24) Remove upper radi ator hose, bypass hose and
rear i ntake mani fol d hose (Fi g. 42).
Fig. 34 Vacuum and Electrical Connections to Intake
Manifold
Fig. 35 Intake Manifold Plenum Support Bracket
Fig. 36 Quick Connect Fuel Fitting to Fuel Line
Fig. 37 Ignition Coils
(25) Remove i ntake mani fol d bol ts. Remove i ntake
mani fol d.
dures.
(27) Remove i ntake mani fol d seal retai ners screws
(Fi g. 43). Remove i ntake mani fol d gasket.
INSTALLATION
(1) Cl ean al l surfaces of cyl i nder bl ock and cyl i n-
der heads.
(2) Pl ace a drop (approxi matel y 1/4 i n. di ameter)
of Mopar Si l i cone Rubber Adhesi ve Seal ant or
equi val ent, onto each of the four mani fol d to cyl i nder
head gasket corners (Fi g. 44).
(3) Careful l y i nstal l the new i ntake mani fol d gas-
ket (Fi g. 43). Torque end seal retai ner screws to 12
Nm (105 i n. l bs.).
(4) I nstal l i ntake mani fol d and bol ts and torque to
1 Nm (10 i n. l bs.). Then torque bol ts to 22 Nm (200
i n. l bs.) i n sequence shown i n (Fi g. 42). Then torque
agai n to 22 Nm (200 i n. l bs.). After i ntake mani fol d
i s i n pl ace, inspect to make sure seals are in
place.
Fig. 38 Intake Manifold Plenum Bolts and Nuts
Fig. 39 Fuel Rail Attaching Bolts
Connector
Fig. 41 Fuel Rail Removal
(5) Make sure the i njector hol es are cl ean and al l
pl ugs have been removed.
(6) Lube i njector O-ri ng wi th a drop of cl ean
seated i n the ports (Fi g. 41).
(8) I nstal l the fuel rai l attachi ng bol ts and torque
to 22 Nm (200 i n. l bs.) (Fi g. 39).
(9) I nstal l fuel tube retai ni ng bracket screw and
torque to 4 Nm (35 i n. l bs.) (Fi g. 39).
(10) Connect cam sensor and cool ant temperature
sensor (Fi g. 40).
(11) Remove coveri ng on l ower i ntake mani fol d
and cl ean surface.
(12) Pl ace the new i ntake mani fol d gasket on
l ower mani fol d. Put upper mani fol d i nto pl ace and
i nstal l bol ts and nuts fi nger ti ght.
NOTE: At no time should the studs be replaced
with a bolt and washer.
(13) I nstal l the generator bracket to i ntake mani -
fol d bol t and the cyl i nder head to i ntake mani fol d
strut bol ts. (Do not torque.)
(14) Torque i ntake mani fol d bol ts to 28 Nm (250
i n. l bs.) fol l owi ng torque sequence i n (Fi g. 38).
(15) Torque generator bracket to i ntake mani fol d
bol t to 54 Nm (40 ft. l bs.).
(16) Torque the cyl i nder head to i ntake mani fol d
strut bol ts to 54 Nm (40 ft. l bs.) (Fi g. 35).
(17) Connect ground strap and MAP sensor el ectri -
cal connectors.
(18) Connect vacuum harness to i ntake pl enum
(Fi g. 34).
(19) Usi ng a new gasket, connect the EGR tube
fl ange to the i ntake mani fol d and torque to 22 Nm
(200 i n. l bs.).
(20) Cl i p wi ri ng harness i nto the hol e i n the throt-
tl e cabl e bracket.
(21) Connect the wi ri ng connectors to the throttl e
posi ti on sensor (TPS) and Automati c I dl e Speed (AI S)
motor (Fi g. 33).
(22) Connect vacuum harness to throttl e body (Fi g.
33).
(23) I nstal l the di rect i gni ti on system (DI S) coi l s.
Torque fasteners to 12 Nm (105 i n. l bs.) (Fi g. 37).
(24) Lubri cate the end of the chassi s fuel tube
wi th 30 wt. oi l . Connect fuel suppl y hose to chassi s
fuel tube assembl y. Pul l back on the qui ck connect
fi tti ng to ensure compl ete i nserti on (Fi g. 36). (Refer
to Fuel Hoses, Cl amps and Qui ck Connect Fi tti ngs i n
Group 14 Fuel Systems).
(25) I nstal l throttl e cabl e. Refer to Group 14 Fuel
(26) Connect fuel i njector wi ri ng harness.
(27) I nstal l ai r cl eaner and hose assembl y.
(28) Connect negati ve battery cabl e. Fi l l Cool i ng
System. See Cool i ng System, Group 7.
(29) Wi th the DRB Scan Tool use ASD Fuel Sys-
tem Test to pressuri ze system to check for l eaks.
Fig. 42 Intake Manifold Removal and Installation
Fig. 43 Intake Manifold Gasket
Fig. 44 Intake Manifold Gasket Sealing
The Auto Shutdown (ASD) Relay will remain ener-
gized for 7 minutes or until the ignition switch is
turned to the OFF position, or Stop All Test is
selected.
EXHAUST MANIFOLDS 3. 3/3. 8L ENGINE
REMOVAL
(2) Remove accessory dri ve bel t. Refer to Accessory
Dri ve secti on l ocated i n Group 7 Cool i ng System for
procedure.
(3) Remove generator.
(4) Rai se vehi cl e and di sconnect exhaust pi pe
from rear (cowl si de) exhaust mani fol d at fl ex-joi nt.
(5) Di sconnect down stream oxygen sensor connec-
tor.
(6) Lower exhaust system to gai n access to rear
mani fol d.
(7) Separate EGR tube from rear mani fol d and
di sconnect Heated Oxygen Sensor l ead wi re (Fi g. 45).
(8) Remove heat shi el d from rear engi ne mount.
(9) Remove Generator/Power Steeri ng Support
Strut (Fi g. 45).
(10) Remove bol ts attachi ng crossover pi pe to
(11) Di sconnect up stream oxygen sensor connec-
tor.
(12) Remove bol ts attachi ng rear mani fol d to cyl -
i nder head and remove mani fol d.
(13) Lower vehi cl e and remove screws attachi ng
front heat shi el d to front mani fol d (Fi g. 46).
(14) Remove bol ts fasteni ng crossover pi pe to
front exhaust mani fol d and nuts fasteni ng mani fol d
to cyl i nder head. Remove assembl i es (Fi g. 47).
dures.
INSTALLATION
(1) I nstal l rear exhaust mani fol d and ti ghten
attachi ng bol ts to 23 Nm (200 i n. l bs.).
(2) I nstal l generator.
NOTE: Inspect crossover pipe fasteners for dam-
age from heat and corrosion. Replace if necessary.
(3) Usi ng new gasket attach crossover pi pe to
exhaust mani fol d and ti ghten bol ts to 54 Nm (40 ft.
l bs.) and connect oxygen sensor l ead (Fi g. 45).
(4) I nstal l EGR Tube and Generator/Power Steer-
i ng Strut (Fi g. 45).
(5) Usi ng new gaskets i nstal l front exhaust mani -
fol d and ti ghten attachi ng bol ts to 23 Nm (200 i n.
l bs.).
(6) Attach exhaust crossover wi th a new gasket
and ti ghten fasteners to 54 Nm (40 ft. l bs.) (Fi g. 47).
(7) Connect up stream oxygen sensor connector.
(8) I nstal l exhaust system.
Fig. 45 EGR Tube, Heated Oxygen Sensor and
Generator/Power Steering Strut
Fig. 46 Heat ShieldFront
Fig. 47 Crossover Pipe
(9) Attach exhaust pi pe to exhaust mani fol d usi ng
new gasket and ti ghten bol ts to 28 Nm (250 i n. l bs.).
(10) Connect down stream oxygen sensor connec-
tor.
(11) I nstal l front mani fol d heat shi el d and ti ghten
attachi ng screws to 12 Nm (105 i n. l bs.) (Fi g. 46).
(12) I nstal l accessory dri ve bel t. Refer to Accessory
Dri ve secti on l ocated i n Group 7 Cool i ng System for
procedure.
INTAKE MANIFOLD
INSPECTION
Check for:
Damage and cracks of each secti on.
Cl ogged water passages i n end cross-overs (i f
equi pped).
Check for cyl i nder head mounti ng surface di stor-
ti on usi ng a strai ghtedge and thi ckness gauge. Refer
to speci fi cati ons for warpage speci fi cati on.
CLEANING
Remove the gasket materi al from the mani fol d sur-
faces.
Be careful not to gouge or scratch the seal i ng sur-
face.
EXHAUST MANIFOLD
INSPECTION
I nspect exhaust mani fol ds for damage or cracks
and check di storti on of the cyl i nder head mounti ng
surface and exhaust cross-over mounti ng surface
wi th a strai ghtedge and thi ckness gauge (Fi g. 48).
CLEANING
Remove the gasket materi al from the mani fol d sur-
faces (i f equi pped). Be careful not to gouge or scratch
the seal i ng surface.
Fig. 48 Check Exhaust Manifold Mounting
SPECIFICATIONS
TORQUE CHART
DESCRIPTION TORQUE
Band Clamp (Torca)
Fastener . . . . . . . . . . . . . . . . . .75 Nm (55 ft. l bs.)
Exhaust Manifold2.4L
Fastener . . . . . . . . . . . . . . . . .23 Nm (200 i n. l bs.)
Exhaust Manifold3.0L
Nuts . . . . . . . . . . . . . . . . . . . .22 Nm (191 i n. l bs.)
Exhaust Manifold3.3/3.8L
Exhaust Manifold3.3/3.8L
Stud . . . . . . . . . . . . . . . . . . . .23 Nm (200 i n. l bs.)
Exhaust Manifold Heat Shield3.0L
Exhaust Manifold Heat Shield3.3/3.8L
Exhaust Manifold Crossover3.0L
Bol ts . . . . . . . . . . . . . . . . . . . . .69 Nm (51 ft. l bs.)
Exhaust Manifold Crossover3.3/3.8L
Fasteners. . . . . . . . . . . . . . . . . .54 Nm (40 ft. l bs.)
Exhaust Manifold Flange (All)
Heat ShieldMuffler
Fastener . . . . . . . . . . . . . . . . . . .2 Nm (23 i n. l bs.)
Heat ShieldToe Board
Fastener . . . . . . . . . . . . . . . . . . .2 Nm (23 i n. l bs.)
Insulator Mounting Bracket
on Muffler to Body
Bol ts . . . . . . . . . . . . . . . . . . . .28 Nm (250 i n. l bs.)
Insulator Mounting Bracket
on Resonator to Body
Bol ts . . . . . . . . . . . . . . . . . . . .28 Nm (250 i n. l bs.)
Intake Manifold Gasket Retainer
IntakeAir Plenum3.0L
Bol ts . . . . . . . . . . . . . . . . . . . .15 Nm (130 i n. l bs.)
Intake (Cross) Manifold3.0L
Bol ts . . . . . . . . . . . . . . . . . . . .20 Nm (174 i n. l bs.)
Intake PlenumSupport Bracket3.3/3.8L
Fastener . . . . . . . . . . . . . . . . . .54 Nm (40 ft. l bs.)
Intake Manifold2.4L
Intake Manifold Upper2.4L
Bol ts . . . . . . . . . . . . . . . . . . . .28 Nm (250 i n. l bs.)
Intake Manifold3.3/3.8L
Intake Manifold Plenum3.3/3.8L
Bol ts . . . . . . . . . . . . . . . . . . . .28 Nm (250 i n. l bs.)
Muffler Hanger Support Clamp
FRAME AND BUMPERS
CONTENTS
page page
BUMPERS AND FASCIA . . . . . . . . . . . . . . . . . . . . 1 FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
BUMPERS AND FASCIA
INDEX
page page
FRONT BUMPER FASCIA . . . . . . . . . . . . . . . . . . 1
FRONT BUMPER REINFORCEMENT . . . . . . . . . . 1
REAR BUMPER FASCIA . . . . . . . . . . . . . . . . . . . 2
REAR BUMPER REINFORCEMENT . . . . . . . . . . . 2
FRONT BUMPER FASCIA
REMOVAL
(2) Remove bol ts hol di ng fasci a to headl amp
mounti ng panel at each si de of gri l l e.
(4) Remove front wheel s. Refer to Group 22,
Wheel s and Ti res, for proper procedures and
sequence.
(5) Remove front wheel house spl ash shi el ds fasten-
ers as necessary to gai n access to bol ts hol di ng front
fasci a to fender. Refer to Group 23, Body, for proper
procedures.
(6) Remove bol ts hol di ng fasci a to bottom of front
fenders (Fi g. 1).
(7) Remove bol ts hol di ng bottom of fasci a/ai r dam
to radi ator cl osure panel .
(8) Di sconnect fog l amp/parki ng and turn si gnal
l amp wi re connector, i f necessary.
(9) Remove bumper fasci a from vehi cl e.
INSTALLATION
(1) Posi ti on front bumper fasci a on vehi cl e.
(3) I nstal l bol ts to hol d fasci a to headl amp mount-
i ng panel at each si de of gri l l e.
(5) I nstal l bol ts to hol d fasci a to bottom of front
fenders (Fi g. 1). The fasci a shoul d be fl ush to fender.
(6) I nstal l front wheel house spl ash shi el ds fasten-
ers. Refer to Group 23, Body, for proper procedures.
(7) I nstal l front wheel s. Refer to Group 22, Wheel s
and Ti res, for proper procedures and ti ghteni ng
sequence.
(8) I nstal l bol ts to hol d bottom of fasci a to radi ator
cl osure panel .
FRONT BUMPER REINFORCEMENT
REMOVAL
(1) Remove front bumper fasci a.
(2) Support front bumper rei nforcement on a sui t-
abl e l i fti ng devi ce.
(3) Remove nuts hol di ng front bumper rei nforce-
ment to frame rai l (Fi g. 2).
Fig. 1 Front Bumper Fascia
NS FRAME AND BUMPERS 13 - 1
(4) Remove front bumper rei nforcement from vehi -
cl e.
INSTALLATION
(1) Posi ti on front bumper rei nforcement on vehi cl e.
(2) I nstal l nuts to hol d rei nforcement to frame
rai l s. Ti ghten nuts to 54 Nm (40 ft. l bs.) torque.
(3) I nstal l front fasci a.
REAR BUMPER FASCIA
REMOVAL
(3) Remove screws hol di ng rear fasci a to rear fas-
ci a brackets (Fi g. 3).
(4) Remove pl asti c ri vets hol di ng bottom of rear
fasci a to bumper rei nforcement.
(5) Di sengage hooks on si des of fasci a from tabs i n
rear fasci a brackets.
(6) Remove rear fasci a from vehi cl e.
INSTALLATION
(1) Posi ti on rear fasci a on vehi cl e.
(2) Engage fasci a tabs under l i ftgate.
(3) Engage hooks on si des of fasci a to tabs i n rear
fasci a brackets.
NOTE: Verify all fascia tabs are still engaged under
the liftgate. Ensure acceptable and consistent gap
between liftgate and fascia.
(4) I nstal l pl asti c ri vets to hol d bottom of rear fas-
ci a to bumper rei nforcement.
(5) I nstal l screws hol di ng rear fasci a to rear fasci a
brackets.
REAR BUMPER REINFORCEMENT
REMOVAL
(1) Remove rear bumper fasci a.
(2) Support rear bumper rei nforcement on a sui t-
abl e l i fti ng devi ce.
(3) Mark posi ti on of nuts on frame rai l extensi ons
to ai d i nstal l ati on.
(4) Remove nuts hol di ng rear bumper rei nforce-
ment to frame rai l extensi ons (Fi g. 4).
(5) Remove rear bumper rei nforcement from vehi cl e.
INSTALLATION
(1) Posi ti on rear bumper rei nforcement on vehi cl e.
(2) Loosel y i nstal l nuts to hol d rear bumper rei n-
forcement to frame rai l extensi ons (Fi g. 4).
(3) Al i gn nuts to previ ousl y made marks on frame
rai l extensi ons. Ti ghten nuts to 27 Nm (20 ft. l bs.)
torque.
(4) I nstal l rear bumper fasci a.
Fig. 2 Front Bumper Reinforcement
Fig. 3 Rear Bumper Fascia
Fig. 4 Rear Bumper Reinforcement
13 - 2 FRAME AND BUMPERS NS
FRAME
INDEX
page page
FRONT CROSSMEMBER MOUNT BUSHINGS . . . 5
FRONT CROSSMEMBER . . . . . . . . . . . . . . . . . . . 3
SPECIFICATIONS
FRAME AND BODY OPENING DIMENSIONS . . . . 5
FRONT CROSSMEMBER
The front suspensi on crossmember must be
i nstal l ed i n the desi gn l ocati on to achi eve proper
front end suspensi on al i gnment. I f the crossmember
i s removed wi thout appl yi ng reference marks on the
frame rai l s, al i gn the crossmember accordi ng to the
di mensi ons provi ded i n thi s group.
NOTE: If the caged nuts in the frame rails become
damaged and cannot be reused, a replacement nut
can be obtained through a Mopar Parts supplier.
REMOVAL
(2) Remove steeri ng col umn l ower cover from
i nstrument panel . Refer to Group 8E, I nstrument
Panel and Systems.
(3) Remove knee bl ocker rei nforcement. Refer to
(4) Posi ti on steeri ng so front wheel s are strai ght
ahead.
CAUTION: Do not rotate steering wheel after disen-
gaging lower coupling from steering gear, damage
to airbag clock spring can result.
(5) Remove cl i nch bol t hol di ng steeri ng col umn
coupl i ng to steeri ng gear shaft (Fi g. 1).
(6) Remove steeri ng col umn coupl i ng from tel e-
scopi ng steeri ng gear shaft.
(8) Posi ti on a drai n pan under power steeri ng
pump and oi l return hose coupl i ng.
(9) Usi ng a hose pi nch-off pl i ers (C-4390), pi nch
power steeri ng oi l return hose off between the cross-
member coupl i ng and the pump.
(10) Loosen hose cl amp at the crossmember cou-
pl i ng.
(11) Di sconnect return hose from metal tube.
(12) Whi l e hol di ng pressure rel i ef val ve nut on
back of power steeri ng pump, Remove fl are nut hol d-
i ng hi gh pressure hose to back of pump.
(13) Separate hi gh pressure hose from pump.
(14) Al l ow power steeri ng fl ui d to drai n i nto pan.
(15) Remove bol ts hol di ng anti -l ock brake sensor
l eads to crossmember.
(16) Posi ti on anti -l ock brake l eads out of the way.
(17) Di sconnect stabi l i zer bar l i nks from ends of
stabi l i zer bar. Refer to Group 2, Suspensi on.
(18) Di sconnect l ower bal l joi nts from l ower control
arms. Refer to Group 2, Suspensi on.
(19) Remove bol t hol di ng rear engi ne mount to
crossmember (Fi g. 2).
(20) Usi ng pai nt or grease penci l , mark outl i ne of
crossmember on frame rai l s to ai d i nstal l ati on.
(21) Support crossmember on sui tabl e l i fti ng
devi ce (Fi g. 4).
(22) Remove bol ts hol di ng crossmember to front
frame rai l s (Fi g. 3).
(23) Remove crossmember from vehi cl e (Fi g. 4).
Fig. 1 Steering Coupling Boot
INSTALLATION
NOTE: If crossmember requires replacement. Refer
to Group 2, Suspension, to transfer suspension
components and Group 19, Steering, to transfer
steering components.
(1) Support crossmember on sui tabl e l i fti ng devi ce
(Fi g. 4).
(2) Posi ti on crossmember to vehi cl e.
(3) Loosel y i nstal l bol ts to hol d crossmember to
front frame rai l s.
(4) Al i gn crossmember to previ ousl y made marks
on frame rai l s.
(5) Ti ghten bol ts hol di ng crossmember to frame
rai l s.
(6) I nstal l bol t hol di ng rear engi ne mount to cross-
member.
Fig. 4 Crossmember
Fig. 2 Rear Engine Mount
Fig. 3 Crossmember Mount
(7) Connect l ower bal l joi nts to l ower control arms.
Refer to Group 2, Suspensi on.
(8) Connect stabi l i zer bar l i nks to ends of stabi -
l i zer bar. Refer to Group 2, Suspensi on.
(9) I nstal l bol ts to hol d anti -l ock brake sensor
l eads to crossmember.
(10) I nstal l hi gh pressure hose to pump.
(11) Connect return hose to metal tube.
(12) Ti ghten hose cl amp at the crossmember cou-
pl i ng.
(13) Remove pi nch-off pl i ers.
(14) Posi ti on steeri ng so front wheel s are strai ght
ahead.
(15) I nstal l steeri ng col umn coupl i ng to tel escopi ng
steeri ng gear shaft.
(16) I nstal l cl i nch bol t to hol d steeri ng col umn cou-
pl i ng to steeri ng gear shaft.
(17) I nstal l knee bl ocker rei nforcement. Refer to
(18) I nstal l steeri ng col umn l ower cover from
i nstrument panel . Refer to Group 8E, I nstrument
Panel and Systems.
FRONT CROSSMEMBER MOUNT BUSHINGS
REMOVAL
(1) Usi ng pai nt or grease penci l , mark outl i ne of
crossmember on frame rai l s.
(2) Loosen bol ts hol di ng crossmember to frame
rai l s.
(3) Remove bol t on bushi ng that requi res repl ace-
ment.
(4) Al l ow crossmember to drop down enough to
gai n cl earance for bushi ng removal .
(5) Remove bushi ng from vehi cl e.
INSTALLATION
(1) Appl y rubber l ube or soap to repl acement bush-
i ng.
(2) I nsert l ower hal f of bushi ng i nto square hol e i n
crossmember.
(3) Pl ace upper hal f of bushi ng on top of cross-
member al i gned to recei ve square tube protrudi ng
upward from l ower bushi ng hal f.
(4) Squeeze bushi ng hal ves together to ensure they
are properl y mated.
(5) Li ft crossmember upward to cl ose gap between
the bushi ng and frame.
(6) Veri fy that l ower bushi ng i s ful l y seated i nto
crossmember and upper bushi ng.
(7) I nstal l bol t to hol d bushi ng and crossmember
to frame rai l hand ti ght.
(8) Al i gn crossmember to reference marks on
frame rai l s.
(9) Ti ghten crossmember to frame rai l s attachi ng
bol ts to 163 Nm (120 ft. l bs.) torque.
SPECIFICATIONS
FRAME AND BODY OPENING DIMENSIONS
Frame di mensi ons are l i sted i n metri c scal e. Al l
di mensi ons are from center to center of Pri nci pal
Locati ng Poi nt (PLP), or from center to center of PLP
and fastener l ocati on.
VEHICLE PREPARATION
Posi ti on the vehi cl e on a frame al i gnment rack,
refer to i nstructi ons provi ded wi th equi pment bei ng
used. Adjust the vehi cl e PLP hei ghts to the speci fi ed
di mensi on above the work surface (datum l i ne). Ver-
ti cal di mensi ons can be taken from the datum l i ne to
the l ocati ons i ndi cated were appl i cabl e. Refer to (Fi g.
5), (Fi g. 6), (Fi g. 7), (Fi g. 8), (Fi g. 9), (Fi g. 10) and
(Fi g. 11) for proper di mensi ons.
Fig. 5 Front Crossmember Dimensions
Fig. 6 Engine Compartment Top View
F
i
g
.
7
E
n
g
i
n
e
C
o
m
p
a
r
t
m
e
n
t
a
n
d
F
r
a
m
e
R
a
i
l
S
i
d
e
V
i
e
w
F
i
g
.
8
F
u
l
l
V
e
h
i
c
l
e
B
o
t
t
o
m
V
i
e
w
Fig. 9 Windshield Opening
Fig. 10 Liftgate Opening
F
i
g
.
1
1
B
o
d
y
S
i
d
e
O
p
e
n
i
n
g
s
FRAME AND BUMPERS
CONTENTS
page
FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
FRAME
INDEX
page page
FRONT TOW HOOK BRACKET . . . . . . . . . . . . . 1
REAR TOW HOOK BRACKET . . . . . . . . . . . . . . 1
FRONT TOW HOOK BRACKET
REMOVAL
(1) Hoi st and support vehi cl e. Refer to Group 0,
Lubri cati on and Mai ntenance, for proper l i fti ng pro-
cedures.
(2) Remove screws hol di ng the bottom of the front
fasci a to the l ower radi ator crossmember.
(3) Remove front tow hook eyel et from front tow
hook bracket.
(4) Support engi ne and transaxl e assembl y usi ng
sui tabl e support stand.
(5) Remove bol ts hol di ng front tow hook bracket to
l ower radi ator crossmember.
(6) Separate front tow hook bracket from vehi cl e.
INSTALLATION
(1) Posi ti on front tow hook bracket to vehi cl e.
(2) I nstal l bol ts to hol d front tow hook bracket to
l ower radi ator crossmember.
(3) Remove support stand from under engi ne and
transaxl e assembl y.
(4) I nstal l front tow hook eyel et to front tow hook
bracket.
(5) I nstal l screws to hol d the bottom of the front
fasci a to the l ower radi ator crossmember.
REAR TOW HOOK BRACKET
REMOVAL
(1) Hoi st and support vehi cl e. Refer to Group 0,
Lubri cati on and Mai ntenance, for proper l i fti ng pro-
cedure.
(2) Remove bol ts hol di ng rear tow hook bracket to
rear frame rai l (Fi g. 2).
Fig. 1 Front Tow Hook Bracket
NS/GS FRAME AND BUMPERS 13 - 1
(3) Separate rear tow hook bracket from vehi cl e.
INSTALLATION
(1) Posi ti on rear tow hook bracket on vehi cl e.
(2) I nstal l bol ts to hol d rear tow hook bracket to
rear frame rai l .
Fig. 2 Rear Tow Hook Bracket
13 - 2 FRAME AND BUMPERS NS/GS
FUEL SYSTEM
CONTENTS
page page
FUEL DELIVERY SYSTEM . . . . . . . . . . . . . . . . . . . 4
FUEL INJECTION SYSTEM . . . . . . . . . . . . . . . . . 29
GENERAL INFORMATION
INDEX
page page
GENERAL INFORMATION
CRUISING RANGE . . . . . . . . . . . . . . . . . . . . . . . . 3
E-85 GENERAL INFORMATION . . . . . . . . . . . . . . 2
ETHANOL FUEL (E-85) . . . . . . . . . . . . . . . . . . . . 2
FUEL REQUIREMENTS . . . . . . . . . . . . . . . . . . . . 1
FUEL REQUIREMENTS . . . . . . . . . . . . . . . . . . . . 2
GASOLINE/OXYGENATE BLENDS . . . . . . . . . . . . 2
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . 1
PCM REPLACEMENT . . . . . . . . . . . . . . . . . . . . . 1
REPLACEMENT PARTS . . . . . . . . . . . . . . . . . . . . 3
STARTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
GENERAL INFORMATION
INTRODUCTION
Throughout thi s group, references may be made to
a parti cul ar vehi cl e by l etter or number desi gnati on.
A chart showi ng the breakdown of these desi gnati ons
i s i ncl uded i n the I ntroducti on Secti on at the front of
The Evaporati on Control System, i s al so consi dered
part of the fuel system. The system reduces the emi s-
si on of fuel vapor i nto the atmosphere.
The descri pti on and functi on of the Evaporati on
Control System i s found i n Group 25 of thi s manual .
PCM REPLACEMENT
THE VEHICLES ORIGINAL MILEAGE. IF THIS
STEP IS NOT DONE A DIAGNOSTIC TROUBLE
FUEL REQUIREMENTS
Your vehi cl e was desi gned to meet al l emi ssi on reg-
ul ati ons and provi de excel l ent fuel economy when
usi ng hi gh qual i ty unl eaded gasol i ne.
Use unl eaded gasol i nes havi ng a mi ni mum posted
octane of 87.
I f your vehi cl e devel ops occasi onal l i ght spark
knock (pi ng) at l ow engi ne speeds thi s i s not harm-
ful . However; conti nued heavy knock at hi gh speeds
can cause damage and shoul d be reported to your
deal er i mmedi atel y. Engi ne damage as a resul t of
heavy knock operati on may not be covered by the
new vehi cl e warranty.
I n addi ti on to usi ng unl eaded gasol i ne wi th the
proper octane rati ng, those that contai n detergents,
corrosi on and stabi l i ty addi ti ves are recommended.
Usi ng gasol i nes that have these addi ti ves wi l l hel p
i mprove fuel economy, reduce emi ssi ons, and mai n-
tai n vehi cl e performance.
Poor qual i ty gasol i ne can cause probl ems such as
hard starti ng, stal l i ng, and stumbl e. I f you experi -
ence these probl ems, try another brand of gasol i ne
before consi deri ng servi ce for the vehi cl e.
NS FUEL SYSTEM 14 - 1
GASOLINE/OXYGENATE BLENDS
Some fuel suppl i ers bl end unl eaded gasol i ne wi th
materi al s that contai n oxygen such as al cohol , MTBE
(Methyl Terti ary Butyl Ether) and ETBE (Ethyl Ter-
ti ary Butyl Ether). Oxygenates are requi red i n some
areas of the country duri ng wi nter months to reduce
carbon monoxi de emi ssi ons. The type and amount of
oxygenate used i n the bl end i s i mportant.
The fol l owi ng are general l y used i n gasol i ne
bl ends:
Ethanol - (Ethyl or Grai n Al cohol ) properl y
bl ended, i s used as a mi xture of 10 percent ethanol
and 90 percent gasol i ne. Gasol i ne bl ended wi th etha-
nol may be used i n your vehi cl e.
MTBE/ETBE - Gasol i ne and MTBE (Methyl Ter-
ti ary Butyl Ether) bl ends are a mi xture of unl eaded
gasol i ne and up to 15 percent MTBE. Gasol i ne and
ETBE (Ethyl Terti ary Butyl Ether) are bl ends of gas-
ol i ne and up to 17 percent ETBE. Gasol i ne bl ended
wi th MTBE or ETBE may be used i n your vehi cl e.
Methanol - Methanol (Methyl or Wood Al cohol ) i s
used i n a vari ety of concentrati ons bl ended wi th
unl eaded gasol i ne. You may encounter fuel s contai n-
i ng 3 percent or more methanol al ong wi th other
al cohol s cal l ed cosol vents.
DO NOT USE GASOLINES CONTAINING
METHANOL.
Use of methanol /gasol i ne bl ends may resul t i n
starti ng and dri veabi l i ty probl ems and damage cri ti -
cal fuel system components.
Probl ems that are the resul t of usi ng methanol /
gasol i ne bl ends are not the responsi bi l i ty of Chrysl er
Corporati on and may not be covered by the vehi cl e
warranty.
Reformulated Gasoline
Many areas of the country are requi ri ng the use of
cl eaner-burni ng fuel referred to as Reformulated
Gasoline. Reformul ated gasol i nes are speci al l y
bl ended to reduce vehi cl e emi ssi ons and i mprove ai r
qual i ty.
Chrysl er Corporati on strongl y supports the use of
reformul ated gasol i nes whenever avai l abl e. Al though
your vehi cl e was desi gned to provi de opti mum perfor-
mance and l owest emi ssi ons operati ng on hi gh qual -
i ty unl eaded gasol i ne, i t wi l l perform equal l y wel l
and produce even l ower emi ssi ons when operati ng on
reformul ated gasol i ne.
Materials Added to Fuel
I ndi scri mi nate use of fuel system cl eani ng agents
shoul d be avoi ded. Many of these materi al s i ntended
for gum and varni sh removal may contai n acti ve sol -
vents of si mi l ar i ngredi ents that can be harmful to
fuel system gasket and di aphragm materi al s.
E-85 GENERAL INFORMATION
The i nformati on i n thi s secti on i s for Fl exi bl e Fuel
Vehi cl es (FFV) onl y. These vehi cl es can be i denti fi ed
by the uni que Fuel Fi l l er Door Label that states
Ethanol (E-85) or Unl eaded Gasol i ne Onl y. Thi s sec-
ti on onl y covers those subjects that are uni que to
these vehi cl es. Pl ease refer to the other secti ons of
thi s manual for i nformati on on features that are
common between Fl exi bl e Fuel and gasol i ne onl y
powered vehi cl es.
ETHANOL FUEL (E-85)
E-85 i s a mi xture of approxi matel y 85% fuel etha-
nol and 15% unl eaded gasol i ne.
WARNING: Ethanol vapors are extremely flammable
and could cause serious personal injury. Never
have any smoking materials lit in or near the vehi-
cle when removing the fuel filler tube cap (gas cap)
or filling the tank. Do not use E-85 as a cleaning
agent and never use it near an open flame.
FUEL REQUIREMENTS
Your vehi cl e wi l l operate on both unl eaded gasol i ne
wi th an octane rati ng of 87, or E-85 fuel , or any mi x-
ture of these two.
For best resul ts, a refuel i ng pattern that al ternates
between E-85 and unl eaded gasol i ne shoul d be
avoi ded. When you do swi tch fuel s, i t i s recom-
mended that
you do not swi tch when the fuel gauge i ndi cates
l ess than 1/4 ful l
you do not add l ess than 5 gal l ons when refuel -
i ng
you operate the vehi cl e i mmedi atel y after refuel -
i ng for a peri od of at l east 5 mi nutes
Observi ng these precauti ons wi l l avoi d possi bl e
hard starti ng and/or si gni fi cant deteri orati on i n dri v-
abi l i ty duri ng warm up.
NOTE: When the ambient temperature is above
90F, you may experience hard starting and rough
idle following start up even if the above recommen-
dations are followed.
STARTING
The characteri sti cs of E-85 fuel make i t unsui tabl e
for use when ambi ent temperatures fal l bel ow 0F. I n
the range of 0F to 32F, you may experi ence an
i ncrease i n the ti me i t takes for your engi ne to start,
and a deteri orati on i n dri vabi l i ty (sags and/or hesi ta-
ti ons) unti l the engi ne i s ful l y warmed up.
14 - 2 FUEL SYSTEM NS
CRUISING RANGE
Because E-85 fuel contai ns l ess energy per gal l on
than gasol i ne, you wi l l experi ence an i ncrease i n fuel
consumpti on. You can expect your MPG and your
dri vi ng range to decrease by about 30% compared to
gasol i ne operati on.
REPLACEMENT PARTS
Many components i n your Fl exi bl e Fuel Vehi cl e
(FFV) are desi gned to be compati bl e wi th ethanol .
Al ways be sure that your vehi cl e i s servi ced wi th cor-
rect ethanol compati bl e parts.
CAUTION: Replacing fuel system components with
non-ethanol compatible components can damage
your vehicle and may void the warranty.
FUEL DELIVERY SYSTEM
INDEX
page page
FUEL DELIVERY SYSTEM . . . . . . . . . . . . . . . . . . 4
FUEL INJECTORS . . . . . . . . . . . . . . . . . . . . . . . . 5
FUEL LEVEL SENSOR . . . . . . . . . . . . . . . . . . . . . 5
FUEL PRESSURE REGULATOR . . . . . . . . . . . . . . 5
FUEL PUMP MODULE . . . . . . . . . . . . . . . . . . . . . 4
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
PRESSURE-VACUUM FILLER CAP . . . . . . . . . . . 6
QUICK-CONNECT FITTINGS . . . . . . . . . . . . . . . . 6
FUEL INJECTORS . . . . . . . . . . . . . . . . . . . . . . . . 9
FUEL LEVEL SENSOR . . . . . . . . . . . . . . . . . . . . . 9
FUEL PUMP PRESSURE TEST 2.4/3.3/3.8L . . . . . 6
SERVICE PROCEDURES
FUEL SYSTEM PRESSURE RELEASE
PROCEDURE2.4/3.3/3.8L . . . . . . . . . . . . . . . 11
PROCEDURE3.0L ENGINE . . . . . . . . . . . . . 11
HOSES AND CLAMPS . . . . . . . . . . . . . . . . . . . . 12
QUICK-CONNECT FITTINGS . . . . . . . . . . . . . . . 12
ACCELERATOR PEDAL . . . . . . . . . . . . . . . . . . . 26
FUEL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
FUEL INJECTOR RAIL2.4L . . . . . . . . . . . . . . . 18
FUEL INJECTOR RAIL3.0L . . . . . . . . . . . . . . . 19
FUEL INJECTOR RAIL3.3/3.8L . . . . . . . . . . . . 21
FUEL INJECTORS3.0L . . . . . . . . . . . . . . . . . . 25
FUEL INJECTOR2.4L . . . . . . . . . . . . . . . . . . . 24
FUEL INJECTOR3.3/3.8L . . . . . . . . . . . . . . . . . 26
FUEL LEVEL SENSOR . . . . . . . . . . . . . . . . . . . . 15
FUEL PRESSURE REGULATOR . . . . . . . . . . . . . 14
FUEL PUMP INLET STRAINER . . . . . . . . . . . . . 15
FUEL PUMP MODULE . . . . . . . . . . . . . . . . . . . . 13
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
THROTTLE CABLE . . . . . . . . . . . . . . . . . . . . . . 27
SPECIFICATIONS
FUEL TANK CAPACITY . . . . . . . . . . . . . . . . . . . 28
TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
The front wheel dri ve van uses a pl asti c fuel tank
l ocated on the l eft si de of the vehi cl e.
The Fuel Del i very System consi sts of: the el ectri c
fuel pump modul e, fuel fi l ter, tubes/l i nes/hoses, fuel
rai l , and fuel i njectors.
The i n-tank fuel pump modul e contai ns the fuel
pump and pressure regul ator. The pump i s servi ced
as part of the fuel pump modul e. Refer to Fuel Pump
Modul e.
The fuel fi l ter i s a repl aceabl e i n-l i ne fi l ter. The fi l -
ter attaches to a bracket mounted on top of the fuel
tank. Refer to the Mai ntenance Schedul es i n the
I ntroducti on secti on of thi s manual for recommended
fuel fi l ter repl acement i nterval s.
A returnl ess fuel system i s used on al l vehi cl es.
Fuel i s returned through the fuel pump modul e and
back to the fuel tank. A separate fuel return l i ne
from the tank to the engi ne i s no l onger used.
FUEL PUMP MODULE
The fuel pump modul e i s i nstal l ed i n the top of the
fuel tank (Fi g. 1). The fuel pump modul e contai ns the
fol l owi ng:
El ectri c fuel pump
Fuel pump reservoi r
I nl et strai ner
Fuel pressure regul ator
Fuel gauge sendi ng uni t
Fuel suppl y l i ne connecti on
The inlet strainer, fuel pressure regulator
and fuel level sensor are the only serviceable
items. If the fuel pump or electrical wiring har-
ness requires service, replace the fuel pump
module.
ELECTRIC FUEL PUMP
The el ectri c fuel pump i s l ocated i n and i s part of
the fuel pump modul e. I t i s a posi ti ve di spl acement,
gerotor type, i mmersi bl e pump wi th a permanent
magnet el ectri c motor. The pump draws fuel through
a strai ner and pushes i t through the motor to the
outl et. The pump contai ns one check val ve. The
Fig. 1 Fuel Pump Module
check val ve, i n the pump outl et, mai ntai ns pump
pressure duri ng engi ne off condi ti ons. The fuel pump
rel ay provi des vol tage to the fuel pump.
The fuel pump has a maxi mum deadheaded pres-
sure output of approxi matel y 635 kPa (95 psi ). The
regul ator adjusts fuel system pressure to approxi -
matel y 338 kPa (49 psi ).
FUEL PUMP ELECTRICAL CONTROL
Vol tage to operate the el ectri c pump i s suppl i ed
through the fuel pump rel ay. For an el ectri cal opera-
ti onal descri pti on of the fuel pump refer to fuel Pump
Rel ayPCM Output.
ELECTRICAL PUMP REPLACEMENT
The el ectri c fuel pump i s not servi ceabl e. I f the
fuel pump or el ectri cal wi ri ng harness needs repl ace-
ment, the compl ete fuel pump modul e must be
repl aced. Perform the Fuel System Pressure Rel ease
procedure before servi ci ng the fuel pump.
FUEL LEVEL SENSOR
The l evel sensor i s attached to the si de of the fuel
pump modul e. The l evel sensor consi sts of a fl oat, an
arm, and a vari abl e resi stor. As the fuel l evel
i ncreases, the fl oat and arm move up. Thi s decreases
the sendi ng uni t resi stance, causi ng the fuel gauge
on the i nstrument panel to read ful l .
FUEL PRESSURE REGULATOR
The fuel system uses a nonadjustabl e pressure reg-
ul ator that mai ntai ns fuel system pressure at
approxi matel y 338 kPa (49 psi ), 3.3l uses approxi -
matel y 379 kPa (55 psi ). The fuel pressure regul ator
contai ns a di aphragm, cal i brated spri ng and a fuel
return val ve. The spri ng pushes down on the di a-
phragm and cl oses off the fuel return port. System
fuel pressure refl ects the amount of fuel pressure
requi red to open the return port.
The pressure regul ator i s a mechani cal devi ce that
i s NOT control l ed by the PCM or engi ne vacuum.
FUEL INJECTORS
The fuel i njectors are 12 ohm el ectri cal sol enoi ds
(Fi g. 2). The i njector contai ns a pi ntl e that cl oses off
an ori fi ce at the nozzl e end. When el ectri c current i s
suppl i ed to the i njector, the armature and needl e
move a short di stance agai nst a spri ng, al l owi ng fuel
to fl ow out the ori fi ce. Because the fuel i s under hi gh
pressure, a fi ne spray i s devel oped i n the shape of a
hol l ow cone. The sprayi ng acti on atomi zes the fuel ,
addi ng i t to the ai r enteri ng the combusti on chamber.
The i njectors are posi ti oned i n the i ntake mani fol d.
Fuel i njectors are not i nterchangeabl e between
engi nes.
The i njectors are posi ti oned i n the i ntake mani fol d
wi th the nozzl e ends di rectl y above the i ntake val ve
port (Fi g. 3).
FUEL TANK
The fuel tanks of al l Chrysl er Motors bui l t vehi cl es
are equi pped wi th fuel and vapor control s that al l ow
the vehi cl e to pass a ful l 360 rol l over wi thout fuel
l eakage.
Front Wheel Dri ve fuel del i very systems contai n a
fuel tank rol l over val ve. The val ve i s mounted on top
of the fuel tank. The val ve functi ons as a tank pres-
sure control val ve whi l e the vehi cl e i s upri ght, but
contai ns a check val ve that prevents fuel from escap-
i ng from the fuel tank when the vehi cl e i s turned
over.
The fuel fi l l er cap acts as a pressure/vacuum rel i ef
val ve. When ai r pressure i nsi de the fuel tank gets too
hi gh or too l ow, the fuel fi l l er cap opens to rel i eve the
di fference i n pressure.
An evaporati on control system restri cts fuel evapo-
rati on i nto the atmosphere and reduces unburned
Fig. 3 Fuel Injector LocationTypical
hydrocarbons. Vapors from the fuel tank are col l ected
i n a charcoal fi l l ed cani ster. The vapors are hel d i n
the cani ster unti l the engi ne i s operati ng. When the
engi ne i s runni ng, the vapors are drawn through the
i ntake mani fol d i nto the combusti on chambers.
PRESSURE-VACUUM FILLER CAP
The l oss of any fuel or vapor out of the fi l l er neck
i s prevented by the use of a safety fi l l er cap. The cap
wi l l rel ease pressure onl y under si gni fi cant pressure
of 10.9 to 13.45 kPa (1.58 to 1.95 psi ). The vacuum
rel ease for al l gas caps i s between 0.97 and 2.0 kPa
(0.14 and 0.29 psi ). The cap must be repl aced by a
si mi l ar uni t i f repl acement i s necessary.
WARNING: REMOVE FILLER CAP TO RELIEVE
TANK PRESSURE BEFORE REMOVING OR REPAIR-
ING FUEL SYSTEM COMPONENTS.
QUICK-CONNECT FITTINGS
Di fferent types of qui ck-connect fi tti ngs are used to
attach vari ous fuel system components. These are: a
si ngl e-tab type, a two-tab type or a pl asti c retai ner
ri ng type. Some are equi pped wi th safety l atch cl i ps.
Refer to the Removal /I nstal l ati on secti on for more
i nformati on.
CAUTION: The interior components (o-rings, spac-
ers) of quick-connect fitting are not serviced sepa-
rately. Do not attempt to repair damaged fittings or
fuel lines/tubes. If repair is necessary, replace the
complete fuel tube assembly.
Fuel tubes connect fuel system components wi th
pl asti c qui ck-connect fuel fi tti ngs. The fi tti ng con-
tai ns non-servi ceabl e O-ri ng seal s (Fi g. 4).
CAUTION: Quick-connect fittings are not serviced
separately. Do not attempt to repair damaged quick-
connect fittings or fuel tubes. Replace the complete
fuel tube/quick-connect fitting assembly.
The qui ck-connect fi tti ng consi sts of the O-ri ngs,
retai ner and casi ng (Fi g. 4). When the fuel tube
enters the fi tti ng, the retai ner l ocks the shoul der of
the ni ppl e i n pl ace and the O-ri ngs seal the tube.
FUEL PUMP PRESSURE TEST 2. 4/3. 3/3. 8L
WARNING: FUEL SYSTEM PRESSURE MUST BE
RELEASED BEFORE A FUEL SYSTEM HOSE OR
COMPONENT IS DISCONNECTED.
The fuel system operates at approxi matel y 338 kPa
(49 psi ), 3.3L uses approxi matel y 379 kPa (55 psi ).
Check fuel system pressure at the test port on the
fuel rai l (Fi g. 5) or (Fi g. 6).
Fig. 4 Plastic Quick-Connect Fittings
Fig. 5 Fuel Pressure Test Port2.4L
(1) Remove cap from fuel pressure test port on fuel
rai l .
(2) Connect Fuel Pressure Gauge C-4799B to test
port (Fi g. 7).
(3) Pl ace the i gni ti on key i n the ON posi ti on.
Usi ng the DRB scan tool , access ASD Fuel System
Test. The ASD Fuel System Test wi l l acti vate the fuel
pump and pressuri ze the system.
I f the gauge readi ng equal s 338 kPa (49 psi )
3.3L uses approxi matel y 379 kPa (55 psi ) further
testi ng i s not requi red. I f pressure i s not correct,
record the pressure.
I f pressure i s above speci fi cati ons, check for a
ki nked or restri cted fuel return tube (from fi l ter to
pump modul e). I f the fuel return tube i s not pi nched
or restri cted, repl ace the fuel pressure regul ator.
I f fuel pressure i s bel ow speci fi cati ons, refer to
the di agnosi s chart for Fuel Pressure Bel ow Speci fi -
cati ons.
(4) Replace Pressure test port cap when fin-
ished doing pressure test.
Fig. 6 Fuel Pressure Test Port3.3/3.8L
Fig. 7 Checking Fuel Pressure at Fuel Rail
FUEL PRESSURE BELOW SPECIFICATIONS
FUEL LEVEL SENSOR
Thi s procedure tests the resi stance of the l evel sen-
sor i tsel f. I t does not test the l evel sensor ci rcui t.
Refer to Group 8W - Wi ri ng Di agrams for ci rcui t
i denti fi cati on.
The l evel sensor i s a vari abl e resi stor. I ts resi s-
tance changes wi th the amount of fuel i n the tank.
The fl oat arm attached to the sensor moves as the
fuel l evel changes. To test the l evel sensor, connect
an ohmmeter across the sensor si gnal and sensor
ground termi nal s of the fuel pump modul e connector
(Fi g. 8). Move the fl oat l ever to the posi ti ons shown
i n the resi stance chart (Fi g. 8). Record the resi stance
at each poi nt. Repl ace the l evel sensor i f the resi s-
tance i s not wi thi n speci fi cati ons.
FUEL INJECTORS
For fuel i njector di agnosi s, refer to the Fuel I njec-
tor Di agnosi s charts. For poor fuel economy di agnosi s
or engi ne mi ss, al so refer to Transmi ssi on Dri vepl ate
i n thi s secti on.
Fig. 8 Level Sensor Diagnosis
FUEL INJECTOR DIAGNOSIS
SERVICE PROCEDURES
PROCEDURE2. 4/3. 3/3. 8L
WHILE SERVICING THE VEHICLE.
(2) Remove fuel fi l l er cap.
(3) Remove protecti ve cap from fuel pressure test
port on fuel rai l (Fi g. 9) or (Fi g. 10).
(4) Pl ace open end of fuel pressure rel ease hose,
tool number C-4799-1, i nto an approved gasol i ne con-
tai ner. Connect other end of hose C-4799-1 to fuel
pressure test port (Fi g. 11). Fuel pressure wi l l bl eed
off through the hose i nto the gasol i ne contai ner. Fuel
gauge C-4799-B contai ns hose C-4799-1.
(5) Replace Pressure test port cap when fin-
ished doing pressure test.
PROCEDURE3. 0L ENGINE
(1) Remove the Fuel Pump rel ay from the Power
Di stri buti on Center (PDC). For l ocati on of the rel ay,
refer to the l abel on the undersi de of the PDC cover.
(2) Start and run engi ne i t stal l s.
(3) Attemp restarti ng engi ne unti l i t wi l l no l onger
run.
(4) Turn i gni ti on key to OFF posi ti on.
CAUTION: Steps 1, 2, 3 and 4 must be performed to
relieve high pressure fuel from within the fuel rail.
Do not attempt to use the following steps to relieve
this pressure as excessive fuel will be forced into a
cylinder chamber.
(5) Unpl ug connector from any i njector.
(6) Attach one end of a jumper wi re wi th al l i gator
cl i ps (18 gauge or smal l er) to ei ther i njector termi nal .
(7) Connect the other end of the jumper wi re to
the posi ti ve si de of the battery.
(8) Connect one end of a second jumper wi re to the
remai ni ng i njector termi nal .
CAUTION: Supplying power to an injector for more
than 4 seconds will permantely damage the injector.
Do not leave the injector connected to power for
more than 4 seconds.
Fig. 10 Fuel Pressure Test Port3.3/3.8L
Fig. 11 Releasing Fuel Pressure
(9) Momentari l y touch the other end of thi s
jumper wi re to the negati ve termi nal of the battery
for no more than 4 seconds.
(10) Pl ace a rag or towel bel ow the fuel l i ne at the
qui ck connect to the rai l .
(11) Di sconnect the qui ck connect fi tti ng to the
rai l . Refer to Qui ck-Connect Fi tti ngs i n thi s secti on.
(12) Return the fuel pump rel ay to the PDC.
(13) One or more Di agnosti c Troubl e Codes (DTCs)
may have been stored i n the PCM memory due to the
fuel pump rel ay removal . The DRB scan tool must be
used to erase a DTC. Refer to group 25, On-Board
Di agnosti cs.
HOSES AND CLAMPS
I nspect al l hose connecti ons (cl amps and qui ck con-
nect fi tti ngs) for compl eteness and l eaks. Repl ace
cracked, scuffed, or swel l ed hoses. Repl ace hoses that
rub agai nst other vehi cl e components or show si gn of
wear.
Fuel i njected vehi cl es use speci al l y constructed
hoses. When repl aci ng hoses, onl y use hoses marked
EFM/EFI .
When i nstal l i ng hoses, ensure that they are routed
away from contact wi th other vehi cl e components
that coul d rub agai nst them and cause fai l ure. Avoi d
contact wi th cl amps or other components that cause
abrasi ons or scuffi ng. Ensure that rubber hoses are
properl y routed and avoi d heat sources.
The hose cl amps have rol l ed edges to prevent the
cl amp from cutti ng i nto the hose. Onl y use cl amps
that are ori gi nal equi pment or equi val ent. Other
types of cl amps may cut i nto the hoses and cause
hi gh pressure fuel l eaks. Ti ghten hose cl amps to 1
QUICK-CONNECT FITTINGS
REMOVAL
When di sconnecti ng a qui ck-connect fi tti ng, the
retai ner wi l l remai n on the fuel tube ni ppl e.
BEFORE DISCONNECTING A QUICK-CONNECT FIT-
TINGS. REFER TO THE FUEL PRESSURE RELEASE
PROCEDURE.
(2) Perform Fuel Pressure Rel ease Procedure.
Refer to the Fuel Pressure Rel ease Procedure i n thi s
secti on.
(3) Squeeze retai ner tabs together and pul l fuel
tube/qui ck-connect fi tti ng assembl y off of fuel tube
ni ppl e. The retai ner wi l l remai n on fuel tube.
INSTALLATION
CAUTION: Never install a quick-connect fitting
without the retainer being either on the fuel tube or
already in the quick-connect fitting. In either case,
ensure the retainer locks securely into the quick-
connect fitting by firmly pulling on fuel tube and fit-
ting to ensure it is secured.
(1) Usi ng a cl ean l i nt free cl oth, cl ean the fuel tube
ni ppl e and retai ner.
(2) Pri or to connecti ng the fi tti ng to the fuel tube,
coat the fuel tube ni ppl e wi th cl ean 30 wei ght engi ne
oi l .
(3) Push the qui ck-connect fi tti ng over the fuel
tube unti l the retainer seats and a click is heard.
(4) The pl asti c qui ck-connect fi tti ng has wi ndows
i n the si des of the casi ng. When the fi tti ng com-
pl etel y attaches to the fuel tube, the retai ner l ocki ng
ears and the fuel tube shoul der are vi si bl e i n the
wi ndows. I f they are not vi si bl e, the retai ner was not
properl y i nstal l ed (Fi g. 12). Do not rely upon the
audible click to confirm a secure connection.
the Auto Shutdown (ASD) Relay remains energized
for either 7 minutes, until the test is stopped, or
until the ignition switch is turned to the Off posi-
tion.
(5) Use the DRB scan tool ASD Fuel System Test
to pressuri ze the fuel system. Check for l eaks.
FUEL FILTER
The fuel fi l ter mounts to the top of the fuel tank.
The i nl et and outl et tubes are permanentl y attached
to the fi l ter (Fi g. 13).
Fig. 12 Plastic Quick-Connect Fitting/Fuel Tube
Connection
BEFORE DISCONNECTING QUICK-CONNECT FIT-
TINGS AT FUEL FILTER. REFER TO THE FUEL
PRESSURE RELEASE PROCEDURE.
REMOVAL
(1) Perform fuel system pressure rel ease.
(2) Di sconnect qui ck-connect fi tti ngs from fuel
pump modul e and chassi s fuel suppl y tube. Refer to
Qui ck-Connect Fi tti ngs i n thi s secti on.
(3) Remove fi l ter retai ni ng screw (Fi g. 13) and
remove fi l ter from tank.
INSTALLATION
(1) I nstal l fuel fi l ter to tank.
(2) The fuel suppl y (to fi l ter) tube, return tube (to
pump modul e) and fuel suppl y (to chassi s fuel l i ne)
are permanentl y attached the fuel fi l ter. The ends of
the fuel suppl y and return tubes have di fferent si ze
qui ck-connect fi tti ngs.
(3) Appl y a l i ght coati ng of cl ean 30 wei ght engi ne
oi l to the fuel fi l ter ni ppl es. I nstal l fuel tubes. Refer
to Fuel Tubes and Qui ck-Connect Fi tti ngs i n thi s sec-
ti on.
FUEL PUMP MODULE
WARNING: THE FUEL RESERVOIR OF THE FUEL
PUMP MODULE DOES NOT EMPTY OUT WHEN THE
TANK IS DRAINED. THE FUEL IN THE RESERVOIR
WILL SPILL OUT WHEN THE MODULE IS
REMOVED.
REMOVAL
(1) Remove fuel fi l l er cap and perform Fuel Sys-
tem Pressure Rel ease procedure.
(3) I nsert fuel si phon hose i nto fuel fi l l er neck and
push i t i nto the tank.
(4) Drai n fuel tank dry i nto hol di ng tank or a
properl y l abel ed GASOLINE safety contai ner.
(6) Use a transmi ssi on jack to support the fuel
tank. Remove bol ts from fuel tank straps. Lower
tank sl i ghtl y.
(7) Cl ean area around fuel tank modul e and tank
to keep di rt and forei gn materi al out of tank.
(8) Di sconnect fuel l i nes from fuel pump modul e by
depressi ng qui ck connect retai ners wi th thumb and
fore fi nger (Fi g. 14).
(9) Sl i de fuel pump modul e el ectri cal connector
l ock to unl ock.
(10) Push down on connector retai ner (Fi g. 15) and
pul l connector off modul e.
Fig. 13 Fuel Filter
Fig. 14 Fuel Line Retainers and Pump Connector
Lock
Fig. 15 Pump Module Connector Retainer and Lock
(11) Usi ng Speci al Tool 6856, remove pl asti c l ock-
nut countercl ockwi se to rel ease pump modul e (Fi g.
16).
(12) Careful l y remove pump modul e and O-ri ng
from tank (Fi g. 17).
(13) Di scard ol d O-ri ng.
INSTALLATION
(1) Wi pe seal area of tank cl ean and pl ace a new
O-ri ng seal i n posi ti on on pump.
(2) Posi ti on fuel pump i n tank wi th l ocknut.
(3) Ti ghten l ocknut to 53 Nm (43 ft. l bs.).
(4) Connect fuel l i nes.
(5) Pl ug i n el ectri cal connector. Sl i de connector
l ock i nto posi ti on.
(6) Rai se fuel tank, i nstal l bol ts i nto fuel tank
straps and ti ghten.
(7) Lower vehi cl e on hoi st.
(8) Connect negati ve cabl e from battery.
(9) Fi l l fuel tank. Check for l eaks.
(10) I nstal l fuel fi l l er cap.
The fuel pressure regul ator i s part of the fuel
pump modul e (Fi g. 18). Remove the fuel pump mod-
ul e from the fuel tank to access the fuel pressure reg-
ul ator.
WARNING: FUEL SYSTEM PRESSURE MUST BE
RELEASED BEFORE SERVICING ANY FUEL SYS-
TEM COMPONENT. PERFORM THE FUEL SYSTEM
PRESSURE RELEASE PROCEDURE.
REMOVAL
(1) Spread tangs on pressure regul ator retai ner
(Fi g. 18).
(2) Pry fuel pressure regul ator out of housi ng.
(3) Ensure both upper and l ower O-ri ngs were
removed wi th regul ator.
INSTALLATION
(1) Li ghtl y l ubri cate the O-ri ngs wi th cl ean engi ne
oi l and pl ace them i nto openi ng i n pump modul e (Fi g.
19).
(2) Push regul ator i nto openi ng i n pump modul e.
Fig. 16 Fuel Pump Module Lock Nut Removal
Fig. 17 Fuel Pump Module Removal
Fig. 18 Fuel Pressure Regulator
(3) Fol d tangs on regul ator retai ner over tabs on
housi ng.
FUEL PUMP INLET STRAINER
REMOVAL
(1) Remove fuel pump modul e. Refer to Fuel Pump
Modul e Removal i n thi s secti on.
(2) Usi ng a thi n strai ght bl ade screwdri ver, pry
back the l ocki ng tabs on fuel pump reservoi r and
remove the strai ner (Fi g. 20).
(3) Remove strai ner O-ri ng from the fuel pump
reservoi r body.
(4) Remove any contami nants i n the fuel tank by
washi ng the i nsi de of the fuel tank.
INSTALLATION
(1) Lubri cate the strai ner O-ri ng wi th cl ean engi ne
oi l .
(2) I nsert strai ner O-ri ng i nto outl et of strai ner so
that i t si ts evenl y on the step i nsi de the outl et.
(3) Push strai ner onto the i nl et of the fuel pump
reservoi r body. Make sure the l ocki ng tabs on the
reservoi r body l ock over the l ocki ng tangs on the
strai ner.
(4) I nstal l fuel pump modul e. Refer to Fuel Pump
Modul e I nstal l ati on i n thi s secti on.
FUEL LEVEL SENSOR
REMOVAL
Remove fuel pump modul e. Refer to Fuel Pump
Modul e i n thi s secti on.
(1) Depress retai ni ng tab and remove the fuel
pump/l evel sensor connector from the BOTTOM of
the fuel pump modul e el ectri cal connector (Fi g. 21).
NOTE: The pump module harness on TOP of flange
is not serviceable or removable.
(2) Pul l off bl ue l ocki ng wedge (Fi g. 22).
(3) Usi ng a smal l screwdri ver l i ft l ocki ng fi nger
away from termi nal and push termi nal out of connec-
tor (Fi g. 23).
Fig. 19 Fuel Pressure Regulator O-rings
Fig. 20 Inlet Strainer Removal
Fig. 21 Fuel Pump/Level Sensor Electrical
Connector
Fig. 22 Wire Terminal Locking Wedge
(4) Push l evel sensor si gnal and ground termi nal s
out of the connector (Fi g. 24).
(5) I nsert a screwdri ver between the fuel pump
modul e and the top of the l evel sensor housi ng (Fi g.
25). Push l evel sensor down sl i ghtl y.
(6) Sl i de l evel sensor wi res through openi ng fuel
pump modul e (Fi g. 26).
(7) Sl i de l evel sensor out of i nstal l ati on channel i n
modul e.
INSTALLATION
(1) I nsert l evel sensor wi res i nto bottom of openi ng
i n modul e.
(2) Wrap wi res i nto groove i n back of l evel sensor
(Fi g. 27).
(3) Whi l e feedi ng wi res i nto gui de grooves, sl i de
l evel sensor up i nto channel unti l i t snaps i nto pl ace
(Fi g. 28). Ensure tab at bottom of sensor l ocks i n
pl ace.
(4) I nstal l l evel sensor wi res i n connector. Push
the wi res up through the connector and then pul l
them down unti l they l ock i n pl ace. Ensure si gnal
and ground wi res are i nstal l ed i n the correct posi -
ti on.
(5) I nstal l l ocki ng wedge on connector.
(6) Push connector up i nto bottom of fuel pump
modul e el ectri cal connector.
Fig. 23 Wire Terminal Locking Finger
Fig. 24 Removing Wires From Connector
Fig. 25 Loosening Level Sensor
Fig. 26 Level Sensor Removal/Installation
Fig. 27 Groove in Back Side of Level Sensor
(7) I nstal l fuel pump modul e. Refer to Fuel Pump
FUEL TANK
REMOVAL
(2) Remove fuel fi l l er cap and perform Fuel Sys-
tem Pressure Rel ease procedure.
properl y l abel ed GASOLINE safety contai ner.
(6) Di sconnect both the fuel fi l l and fuel vent rub-
ber hoses at the fuel tank.
(7) Di sconnect fuel suppl y l i nes from the steel sup-
pl y l i ne.
The fuel pump module electrical connector
has a retainer that locks it in place.
(8) Sl i de fuel pump modul e el ectri cal connector
l ock to unl ock (Fi g. 29).
(10) Use a transmi ssi on jack to support fuel tank.
Remove bol ts from fuel tank straps.
(11) Lower tank sl i ghtl y. Careful l y remove fi l l er
hose from tank.
(12) Lower the fuel tank. Di sconnect pressure
rel i ef/rol l over val ve hose at the front of tank. Remove
cl amp and remove fuel fi l l er tube vent hose. Remove
fuel tank from vehi cl e.
Fig. 28 Installation Channel
Fuel Tank
Lock
Fig. 30 Pump Module Connector Retainer and Lock
INSTALLATION
(1) Posi ti on fuel tank on transmi ssi on jack. Con-
nect pressure rel i ef/rol l over val ve hose. Connect fuel
fi l l er tube vent hose and repl ace cl amp.
(2) Rai se tank i nto posi ti on and careful l y work
fi l l er tube i nto tank. A l i ght coati ng of cl ean engi ne
oi l on the tube end may be used to ai d assembl y.
(3) Feed fi l l er vent l i ne thru frame rai l . Careful
not to cross l i nes.
(4) Ti ghten strap bol ts to 54 Nm (40 ft. l bs.)
torque. Remove transmi ssi on jack.
(5) Ti ghten fi l l er hose cl amp to 3.3 Nm (30 i n.
l bs.).
CAUTION: Ensure straps are not twisted or bent
before or after tightening strap nuts.
(6) Connect fuel pump/modul e el ectri cal connector.
Pl ace retai ner i n l ocked posi ti on.
(7) Lubri cate the fuel suppl y l i ne wi th cl ean 30
wei ght engi ne oi l , i nstal l the qui ck connect fuel fi t-
ti ng. Refer to Tube/Fi tti ng Assembl y i n the Fuel
Del i very secti on of thi s Group.
(8) Attach fi l l er l i ne to fi l l er tube. Pul l on connec-
tor to make sure of connecti on.
(9) Fi l l fuel tank, repl ace cap, and connect battery
negati ve cabl e.
(10) Use the DRB scan tool ASD Fuel System Test
to pressuri ze the fuel system. Check for l eaks.
FUEL INJECTOR RAIL2. 4L
REMOVAL
before servicing or starting repairs. Refer to
Fuel System Pressure Rel ease Procedure i n thi s sec-
ti on.
(3) Remove ai r cl eaner i nl et hose from throttl e
body.
(i f equi pped) from throttl e l ever.
(5) Remove throttl e cabl es from bracket by com-
pressi ng retai ni ng tabs.
(6) Remove connector from throttl e posi ti on sensor.
(7) Remove connector from i dl e ai r control motor.
(8) Remove vacuum l i nes from i ntake pl enum fi t-
ti ngs (Fi g. 31) and (Fi g. 32).
(9) Remove connector from i ntake ai r temperature
sensor (Fi g. 32).
(10) Remove connector from MAP sensor (Fi g. 33).
(11) Remove fuel hose qui ck connect fi tti ng from
Clamps and Quick Connect Fittings in this Sec-
tion. Pl ace a shop towel under the connecti ons to
absorb any fuel spi l l ed from the fi tti ng.
Fig. 31 Vacuum Fitting on Rear of Intake Manifold
Fig. 32 Electrical and Vacuum Connections
(12) Remove bol t hol di ng bottom of i ntake support
bracket.
(13) Remove i ntake mani fol d screws (Fi g. 35).
(14) Remove fuel rai l attachi ng bol ts.
the i njector O-ri ngs upon removal from thei r ports.
INSTALLATION
(1) Ensure i njector hol es are cl ean. Repl ace
O-ri ngs i f damaged.
(2) Lubri cate i njector O-ri ngs wi th a drop of cl ean
(4) I nstal l the fuel rai l mounti ng bol ts. Ti ghten
bol ts to 22 Nm (200 i n. l bs.) torque (Fi g. 35).
(5) I nstal l a new i ntake mani fol d gasket.
(6) Posi ti on i ntake mani fol d.
(7) Ti ghten retai ni ng bol ts starti ng at center and
progressi ng outward i n both di recti ons to 23 Nm
(200 i n. l bs.) (Fi g. 35). Repeat thi s procedure unti l al l
bol ts are at speci fi ed torque.
(8) I nstal l fuel hose qui ck connector fi tti ng to chas-
si s tubes. Refer to Fuel Hoses, Clamps and
Quick Connect Fittings in this Section. Push the
fi tti ng onto the chassi s tube unti l i t cl i cks i nto pl ace.
Pul l on the fi tti ng to ensure compl ete i nserti on.
(9) Reverse removal procedures Step 2 thru Step
12 for i nstal l ati on.
FUEL INJECTOR RAIL3. 0L
WARNING: THE 3.0L MPI FUEL SYSTEM IS UNDER
A CONSTANT PRESSURE OF APPROXIMATELY 330
KPA (48 PSI). PERFORM FUEL PRESSURE
RELEASE PROCEDURE BEFORE SERVICING THE
FUEL RAIL OR FUEL INJECTORS.
REMOVAL
(1) Perform the Fuel Pressure Rel ease Procedure.
Fig. 33 Map Sensor2.4L
Fig. 35 Intake Manifold Attaching Points
(3) Remove ai r i nl et resonator (Fi g. 36).
(4) Remove throttl e cabl e (Fi g. 37).
(5) Di sconnect el ectri cal connectors from the i dl e
ai r control motor and Throttl e Posi ti on Sensor (TPS).
body (Fi g. 38).
(7) Remove el ectri cal connector from the cool ant
temperature sensor (Fi g. 39).
(8) Remove vacuum connecti ons from ai r i ntake
pl enum vacuum connector (Fi g. 39).
(9) Remove the fuel hose qui ck connect fi tti ng from
Clamps and Quick Connect Fittings in this Sec-
tion. Pl ace a shop towel under the connecti ons to
absorb any fuel spi l l ed from the fi tti ng.
Throttle Body
Connections
(10) Remove ai r i ntake pl enum to i ntake mani fol d
mounti ng fasteners (Fi g. 41).
(12) Remove ai r i ntake pl enum (Fi g. 42).
(13) Cover i ntake mani fol d whi l e servi ci ng i njector
fuel rai l .
(14) Di sconnect fuel i njector wi ri ng harness from
engi ne wi ri ng harness.
CAUTION: Do not damage the injector O-Rings
when removing the injectors and fuel rail assembly.
(15) Remove fuel rai l mounti ng bol ts. Li ft fuel rai l
assembl y off of i ntake mani fol d.
INSTALLATION
(1) Ensure i njectors are seated i nto the recei ver
cup of fuel rai l wi th l ock ri ng i n pl ace.
(2) Make sure the i njector hol es i n the mani fol d
are cl ean.
(3) To ease i nstal l ati on, l ubri cate i njector O-ri ng
wi th a drop of cl ean engi ne oi l .
(5) I nstal l fuel rai l attachi ng bol ts. Ti ghten bol ts to
13 Nm (115 i n. l bs.) torque.
(6) I nstal l fuel suppl y and return tube hol ddown
bol t and the vacuum crossover tube hol ddown bol t.
Ti ghten bol ts to 10 Nm (95 i n. l bs.) torque.
(7) Connect fuel i njector wi ri ng harness to engi ne
wi ri ng harness.
(8) Remove coveri ng from l ower i ntake mani fol d
and cl ean surface.
(9) Pl ace i ntake mani fol d gaskets with beaded
sealer upon l ower mani fol d. Put ai r i ntake i n pl ace.
I nstal l i gni ti on coi l . I nstal l attachi ng fasteners and
ti ghten to 13 Nm (115 i n. l bs.) torque.
(10) Connect fuel l i ne to fuel rai l .
(11) Connect vacuum harness to ai r i ntake pl e-
num.
(12) Connect cool ant temperature sensor el ectri cal
connector to sensor.
(13) Connect PCV and brake booster suppl y hose
to i ntake pl enum.
(14) Connect i dl e ai r control motor and Throttl e
Posi ti on Sensor (TPS) el ectri cal connectors.
(15) Connect vacuum vapor harness to throttl e
body.
(16) I nstal l throttl e cabl e.
(17) I nstal l ai r i nl et resonator.
FUEL INJECTOR RAIL3. 3/3. 8L
WARNING: THE 3.3/3.8L MPI FUEL SYSTEM IS
UNDER A CONSTANT PRESSURE OF APPROXI-
MATELY 330 KPA (49 PSI), 3.3L USES APPROXI-
MATELY 379 KPA (55 PSI). PERFORM FUEL
PRESSURE RELEASE PROCEDURE BEFORE SER-
VICING THE FUEL RAIL OR FUEL INJECTORS.
REMOVAL
dure.
(3) Remove i ntake mani fol d cover.
(4) Remove ai r i nl et resonator (Fi g. 36).
(i f equi pped) (Fi g. 43) from throttl e l ever and
bracket.
Fig. 41 Air Intake Plenum to Intake Manifold
Attaching Fasteners
Fig. 42 Removing Air Intake Plenum
(6) Di sconnect i dl e ai r control motor and Throttl e
Posi ti on Sensor (TPS) el ectri cal connectors (Fi g. 44).
body and i ntake mani fol d (Fi g. 45).
(8) Remove EGR tube to i ntake mani fol d fl ange
bol ts (Fi g. 46).
(9) Remove cyl i nder head to i ntake pl enum strut.
(10) Di sconnect el ectri cal connector from the MAP
sensor (Fi g. 47)
(11) Remove engi ne mounted ground strap.
(12) Remove the fuel hose qui ck connect fi tti ng
from the chassi s tube (Fi g. 48). Refer to Fuel
Hoses, Clamps and Quick Connect Fittings in
this Section.
Throttle Body
Fig. 45 Vacuum Connections
Fig. 46 EGR Tube3.3L/3.8
(13) Remove Di rect I gni ti on System (DI S) coi l s
(Fi g. 49).
(14) Remove generator bracket to i ntake mani fol d
bol t.
(15) Remove i ntake mounti ng mani fol d bol ts and
rotate mani fol d back over rear val ve cover (Fi g. 50).
(17) Remove fuel tube retai ner bracket screw and
fuel rai l attachi ng bol ts (Fi g. 51). Spread the retai ner
bracket to al l ow fuel tube removal cl earance.
(18) Di sconnect camshaft posi ti on sensor (Fi g. 52)
and engi ne cool ant temperature sensor.
the i njector O-ri ngs upon removal from thei r ports
(Fi g. 53).
INSTALLATION
(1) Ensure i njector hol es are cl ean. Repl ace
O-ri ngs i f damaged.
(2) Lubri cate i njector O-ri ngs wi th a drop of cl ean
Fig. 47 Map Sensor
Fig. 49 Ignition Coils
Fig. 50 Intake Manifold Bolts
Fig. 51 Fuel Rail Attaching Bolts
(4) I nstal l the fuel rai l mounti ng bol ts. Ti ghten
bol ts to 22 Nm (200 i n. l bs.) torque (Fi g. 51).
(5) I nstal l fuel tube retai ni ng bracket screw.
Ti ghten screw to 4 Nm (35 i n. l bs.) torque.
(6) Connect el ectri cal connectors to camshaft posi -
ti on sensor and engi ne cool ant temperature sensor.
(7) Remove coveri ng on l ower i ntake mani fol d and
cl ean surface.
(8) Pl ace i ntake mani fol d gasket on l ower mani -
fol d. Put upper mani fol d i nto pl ace and i nstal l bol ts
fi nger ti ght.
(9) I nstal l the generator bracket to i ntake mani -
fol d bol t and the cyl i nder head to i ntake mani fol d
strut bol ts (do not ti ghten.)
(10) Fol l owi ng the ti ghteni ng sequence i n (Fi g. 50),
ti ghten i ntake mani fol d bol ts to 28 Nm (250 i n. l bs.)
torque.
(11) Ti ghten generator bracket to i ntake mani fol d
bol t to 54 Nm (40 ft. l bs.) torque.
(12) Ti ghten the cyl i nder head to i ntake mani fol d
strut bol ts to 54 Nm (40 ft. l bs.) torque.
(13) Connect ground strap and MAP sensor el ectri -
cal connector.
(14) Connect vacuum harness to i ntake pl enum.
Connect PCV system hoses.
(15) Usi ng a new gasket, connect the EGR tube to
the i ntake mani fol d pl enum. Ti ghten screws to 22
(16) Connect el ectri cal connectors to the TPS and
i dl e ai r control motor.
(17) Connect vacuum harness to throttl e body.
(18) I nstal l the di rect i gni ti on system (DI S) coi l s.
Ti ghten fasteners to 12 Nm (105 i n. l bs.) torque.
(19) I nstal l fuel hose qui ck connector fi tti ng to
chassi s tubes. Refer to Fuel Hoses, Clamps and
Quick Connect Fittings in this Section. Push the
fi tti ng onto the chassi s tube unti l i t cl i cks i nto pl ace.
Pul l on the fi tti ng to ensure compl ete i nserti on.
(20) I nstal l throttl e cabl e and speed control cabl e
(i f equi pped).
(21) I nstal l ai r i nl et resonator.
FUEL INJECTOR2. 4L
The fuel rai l must be removed fi rst. Refer to Fuel
I njector Rai l Removal i n thi s secti on.
REMOVAL
(1) Di sconnect i njector wi ri ng connector from i njec-
tor.
(2) Posi ti on fuel rai l assembl y so that the fuel
i njectors are easi l y accessi bl e (Fi g. 54).
(3) Rotate i njector and pul l i njector out of fuel rai l .
The cl i p wi l l stay on the i njector.
(4) Check i njector O-ri ng for damage. I f O-ri ng i s
damaged, i t must be repl aced. I f i njector i s reused, a
protecti ve cap must be i nstal l ed on the i njector ti p to
prevent damage. Repl ace the i njector cl i p i f i t i s dam-
aged.
(5) Repeat for remai ni ng i njectors.
Fig. 52 Camshaft Position Sensor Connector
Fig. 53 Fuel Rail Removal
INSTALLATION
(1) Before i nstal l i ng an i njector the rubber O-ri ng
must be l ubri cated wi th a drop of cl ean engi ne oi l to
ai d i n i nstal l ati on.
(2) I nstal l i njector cl i p by sl i di ng open end i nto the
top sl ot of the i njector. The edge of the recei ver cup
wi l l sl i de i nto the si de sl ots of cl i p.
(3) I nstal l i njector top end i nto fuel rai l recei ver
cap. Be careful not to damage O-ri ng duri ng i nstal l a-
ti on (Fi g. 55).
(4) Repeat steps for remai ni ng i njectors.
(5) Connect fuel i njector wi ri ng.
FUEL INJECTORS3. 0L
WARNING: THE 3.0L MPI FUEL SYSTEM IS UNDER
A CONSTANT PRESSURE OF APPROXIMATELY 330
KPA (48 PSI). PERFORM FUEL PRESSURE
RELEASE PROCEDURE BEFORE SERVICING THE
FUEL INJECTORS.
REMOVAL
(1) Perform the Fuel Pressure Rel ease Procedure.
(3) The fuel rai l must be removed fi rst to servi ce
the i njectors. Refer to Fuel I njector Rai l Assembl y
Removal i n thi s secti on.
(4) Label each i njector connector wi th i ts cyl i nder
number. Di sconnect el ectri cal connector from i njector.
i njectors are easi l y accessi bl e.
(6) Remove i njector cl i p from fuel rai l and i njector
(Fi g. 54).
(7) Pul l i njector strai ght out of fuel rai l recei ver
cup (Fi g. 55).
damaged, i t must be repl aced. I f i njector i s to be
reused, a protecti ve cap must be i nstal l ed on the
i njector ti p to prevent damage.
(9) Repeat procedure for remai ni ng i njectors.
INSTALLATION
(1) Before i nstal l i ng an i njector, the rubber O-ri ng
(2) Bei ng careful not to damage O-ri ng, i nstal l
i njector nozzl e end i nto fuel rai l recei ver cap.
(3) I nstal l i njector cl i p by sl i di ng open end i nto
top slot of the i njector. The edge of the recei ver cup
wi l l sl i de i nto the si de sl ots of cl i p (Fi g. 55)
(5) I nstal l fuel rai l assembl y. Refer to Fuel Rai l
Assembl y I nstal l ati on i n thi s secti on.
(6) Connect el ectri cal connectors to i njectors i n cor-
rect order.
Fig. 54 Fuel Injector and RailTypical
Fig. 55 Servicing Fuel InjectorTypical
FUEL INJECTOR3. 3/3. 8L
The fuel rai l must be removed fi rst. Refer to Fuel
I njector Rai l Assembl y Removal i n thi s secti on.
REMOVAL
(1) Di sconnect i njector wi ri ng connector from i njec-
tor.
i njectors are easi l y accessi bl e (Fi g. 54).
(3) Rotate i njector and pul l i njector out of fuel rai l .
The cl i p wi l l stay on the i njector.
damaged, i t must be repl aced. I f i njector i s reused, a
protecti ve cap must be i nstal l ed on the i njector ti p to
prevent damage. Repl ace the i njector cl i p i f i t i s dam-
aged.
(5) Repeat for remai ni ng i njectors.
INSTALLATION
(1) Before i nstal l i ng an i njector the rubber O-ri ng
(2) I nstal l i njector cl i p by sl i di ng open end i nto the
top sl ot of the i njector. The edge of the recei ver cup
wi l l sl i de i nto the si de sl ots of cl i p (Fi g. 56).
(3) I nstal l i njector top end i nto fuel rai l recei ver
cap. Be careful not to damage O-ri ng duri ng i nstal l a-
ti on (Fi g. 56).
(5) Connect fuel i njector wi ri ng.
ACCELERATOR PEDAL
CAUTION: When servicing the accelerator pedal,
throttle cable or speed control cable, do not dam-
age or kink the core wire inside the cable sheath-
ing.
REMOVAL
(1) Worki ng from the engi ne compartment, remove
the throttl e control shi el d.
(2) Hol d the throttl e body throttl e l ever i n the
wi de open posi ti on. Remove the throttl e cabl e from
the throttl e body cam.
(3) From i nsi de the vehi cl e, hol d up the pedal and
remove the cabl e retai ner and throttl e cabl e from the
upper end of the pedal shaft (Fi g. 57) and (Fi g. 58).
(4) Worki ng from the engi ne compartment, remove
nuts from accel erator pedal attachi ng studs (Fi g. 57).
Remove assembl y from vehi cl e.
INSTALLATION
(1) Posi ti on accel erator pedal assembl y on dash
panel . I nstal l retai ni ng nuts. Ti ghten retai ni ng nuts
to 12 Nm (105 i n. l bs.) torque.
Fig. 56 Servicing Fuel InjectorTypical
Fig. 57 Accelerator Pedal and Throttle CableFront
View
Fig. 58 Accelerator Pedal and Throttle CableRear
View
i nstal l the throttl e cabl e and cabl e retai ner i n the
upper end of the pedal shaft.
(3) From the engi ne compartment, hol d the throt-
tl e body l ever i n the wi de open posi ti on and i nstal l
the throttl e cabl e. I nstal l the throttl e control shi el d.
THROTTLE CABLE
CAUTION: When servicing the accelerator pedal,
throttle cable or speed control cable, do not dam-
age or kink the core wire inside the cable sheath-
ing.
REMOVAL
(1) Worki ng from the engi ne compartment, hol d
the throttl e body throttl e l ever i n the wi de open posi -
ti on.
(2) Remove the throttl e cabl e from the throttl e
body cam (Fi g. 59), (Fi g. 60) and (Fi g. 61).
remove the cabl e retai ner and throttl e cabl e from the
upper end of the pedal shaft (Fi g. 57).
(4) Remove retai ner cl i p from throttl e cabl e and
grommet at dash panel (Fi g. 58).
(5) From the engi ne compartment, pul l the throttl e
cabl e out of the dash panel grommet. The grommet
shoul d remai n i n the dash panel .
(6) Remove the throttl e cabl e from throttl e bracket
by careful l y compressi ng both retai ni ng ears si mul ta-
neousl y. Then gentl y pul l the throttl e cabl e from
throttl e bracket.
INSTALLATION
(1) From the engi ne compartment, push the hous-
i ng end fi tti ng i nto the dash panel grommet.
(2) I nstal l the cabl e housi ng (throttl e body end)
i nto the cabl e mounti ng bracket on the engi ne.
i nstal l throttl e cabl e and cabl e retai ner i n the upper
end of the pedal shaft.
(4) At the dash panel , i nstal l the cabl e retai ner
cl i p between the end of the throttl e cabl e fi tti ng and
grommet (Fi g. 58)
(5) From the engi ne compartment, rotate the
throttl e l ever wi de open and i nstal l the throttl e
cabl e.
Attachment2.4L Engine
Attachment3.0L Engine
Attachment3.3/3.8L Engines
SPECIFICATIONS
TORQUE
DESCRIPTION TORQUE
Fuel Pump Modul e Locknut . . . . .58 Nm (43 ft. l bs.)
Fuel Tank Strap Bol ts . . . . . . . . .54 Nm (40 ft. l bs.)
Fuel Rai l Bol ts2.4L . . . . . . . .22 Nm (200 i n. l bs.)
Fuel Rai l Bol ts3.0L. . . . . . . . .13 Nm (115 i n. l bs.)
Fuel Rai l Bol ts3.3/3.8L . . . . . . .10 Nm (95 i n. l bs.)
Fuel Tube Hol ddown Bol ts3.0L . . . . . . . . . .22 Nm
(200 i n. l bs.)
Fuel Tube Hol ddown Screw . . . . . .4 Nm (35 i n. l bs.)
I ntake Mani fol d Bol ts2.4L . . .22 Nm (200 i n. l bs.)
I ntake Mani fol d Bol ts3.0L . . .13 Nm (115 i n. l bs.)
I ntake Mani fol d Bol ts3.3/3.8L. . . . . . . . . . .28 Nm
(250 i n. l bs.)
Accel erator Pedal to Dash Nuts . . . . . . . . . . .12 Nm
(105 i n. l bs.)
FUEL TANK CAPACITY
Vehicle Liters U.S. Gallons
NS 75.O 20
Nominal refill capacities are shown. A variation may be
observed from vehicle to vehicle due to manufacturing
tolerance and refill procedure.
FUEL INJ ECTION SYSTEM
INDEX
page page
GENERAL INFORMATION
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . 30
MODES OF OPERATION . . . . . . . . . . . . . . . . . . 30
AIR CONDITIONING (A/C) CLUTCH RELAY
PCM OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . 41
AIR CONDITIONING PRESSURE
TRANSDUCERPCM INPUT . . . . . . . . . . . . . 33
AIR CONDITIONING SWITCH SENSE
PCM INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
AUTOMATIC SHUTDOWN (ASD) SENSE
PCM INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
AUTOMATIC SHUTDOWN RELAYPCM
OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
AUTOMATIC TRANSAXLE CONTROL
MODULEPCM OUTPUT . . . . . . . . . . . . . . . . 44
BATTERY VOLTAGEPCM INPUT . . . . . . . . . . . 33
BRAKE SWITCHPCM INPUT . . . . . . . . . . . . . . 33
CAMSHAFT POSITION SENSORPCM INPUT . 33
CCD BUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
CRANKSHAFT POSITION SENSORPCM
INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
DATA LINK CONNECTORPCM OUTPUT . . . . . 44
DUTY CYCLE EVAP CANISTER PURGE
SOLENOIDPCM OUTPUT . . . . . . . . . . . . . . 43
ELECTRONIC EGR TRANSDUCER
SOLENOIDPCM OUTPUT . . . . . . . . . . . . . . 43
PCM INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
FUEL INJECTORSPCM OUTPUT . . . . . . . . . . 44
FUEL PUMP RELAYPCM OUTPUT . . . . . . . . . 42
GENERATOR FIELDPCM OUTPUT . . . . . . . . . 42
HEATED OXYGEN SENSOR (O2S SENSOR)
PCM INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
IDLE AIR CONTROL MOTORPCM OUTPUT . . 42
IGNITION COILPCM OUTPUT . . . . . . . . . . . . . 45
INTAKE AIR TEMPERATURE SENSORPCM
INPUT (2.4L ONLY) . . . . . . . . . . . . . . . . . . . . . 41
KNOCK SENSORPCM INPUT . . . . . . . . . . . . . 38
MALFUNCTION INDICATOR (CHECK ENGINE)
LAMPPCM OUTPUT . . . . . . . . . . . . . . . . . . 46
SENSORPCM INPUT . . . . . . . . . . . . . . . . . . 39
POWERTRAIN CONTROL MODULE (PCM) . . . . 32
PROPORTIONAL PURGE SOLENOID . . . . . . . . . 43
SOLID STATE FAN RELAYPCM OUTPUT . . . . 46
SPEED CONTROL SOLENOIDS
PCM OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . 46
SPEED CONTROLPCM INPUT . . . . . . . . . . . . 39
STARTER RELAYPCM OUTPUT . . . . . . . . . . . 42
SYSTEM DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . 32
TACHOMETERPCM OUTPUT . . . . . . . . . . . . . 47
THROTTLE BODY . . . . . . . . . . . . . . . . . . . . . . . 47
THROTTLE POSITION SENSOR (TPS)
PCM INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
TORQUE CONVERTER CLUTCH SOLENOID
PCM OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . 46
TRANSAXLE PARK/NEUTRAL SWITCH
PCM INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
VEHICLE SPEED AND DISTANCE
PCM INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
ASD AND FUEL PUMP RELAYS . . . . . . . . . . . . . 59
CAMSHAFT AND CRANKSHAFT POSITION
SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
HEATED OXYGEN SENSOR . . . . . . . . . . . . . . . 61
KNOCK SENSOR . . . . . . . . . . . . . . . . . . . . . . . . 61
SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
THROTTLE BODY MINIMUM AIR FLOW
CHECK PROCEDURE . . . . . . . . . . . . . . . . . . . 62
VISUAL INSPECTION2.4L ENGINE . . . . . . . . . 47
VISUAL INSPECTION3.0L ENGINE . . . . . . . . . 52
VISUAL INSPECTION3.3/3.8L ENGINES . . . . . 55
AIR CLEANER ELEMENT . . . . . . . . . . . . . . . . . . 70
AUTOMATIC SHUTDOWN (ASD) RELAY . . . . . . 64
DOWNSTREAM OXYGEN SENSOR . . . . . . . . . . 69
ENGINE COOLANT TEMPERATURE
SENSOR2.4L . . . . . . . . . . . . . . . . . . . . . . . . 70
SENSOR3.0L . . . . . . . . . . . . . . . . . . . . . . . . 71
SENSOR3.3/3.8L . . . . . . . . . . . . . . . . . . . . . 71
FUEL PUMP RELAY . . . . . . . . . . . . . . . . . . . . . . 64
IDLE AIR CONTROL MOTOR . . . . . . . . . . . . . . . 65
KNOCK SENSOR . . . . . . . . . . . . . . . . . . . . . . . . 70
SENSOR2.4/3.3/3.8L . . . . . . . . . . . . . . . . . . 66
SENSOR3.0L . . . . . . . . . . . . . . . . . . . . . . . . 66
PROPORTIONAL PURGE SOLENOID VALVE . . . 66
THROTTLE BODY . . . . . . . . . . . . . . . . . . . . . . . 64
UPSTREAM OXYGEN SENSOR . . . . . . . . . . . . . 68
SPECIFICATIONS
TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
SPECIAL TOOLS
FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
GENERAL INFORMATION
INTRODUCTION
Al l engi nes used i n thi s secti on have a sequenti al
Mul ti -Port El ectroni c Fuel I njecti on system. The MPI
system i s computer regul ated and provi des preci se
ai r/fuel rati os for al l dri vi ng condi ti ons. The Power-
trai n Control Modul e (PCM) operates the fuel i njec-
ti on system.
The PCM regul ates:
I gni ti on ti mi ng
Ai r/fuel rati o
Emi ssi on control devi ces
Cool i ng fan
Chargi ng system
I dl e speed
Vehi cl e speed control
Vari ous sensors provi de the i nputs necessary for
the PCM to correctl y operate these systems. I n addi -
ti on to the sensors, vari ous swi tches al so provi de
i nputs to the PCM.
Al l i nputs to the PCM are converted i nto si gnal s.
The PCM can adapt i ts programmi ng to meet chang-
i ng operati ng condi ti ons.
Fuel i s i njected i nto the i ntake port above the
i ntake val ve i n preci se metered amounts through
el ectri cal l y operated i njectors. The PCM fi res the
i njectors i n a speci fi c sequence. Under most operat-
i ng condi ti ons, the PCM mai ntai ns an ai r fuel rati o
of 14.7 parts ai r to 1 part fuel by constantl y adjust-
i ng i njector pul se wi dth. I njector pul se wi dth i s the
l ength of ti me the i njector i s open.
The PCM adjusts i njector pul se wi dth by openi ng
and cl osi ng the ground path to the i njector. Engi ne
RPM (speed) and mani fol d absol ute pressure (ai r
densi ty) are the pri mary i nputs that determi ne i njec-
tor pul se wi dth.
MODES OF OPERATION
As i nput si gnal s to the PCM change, the PCM
adjusts i ts response to output devi ces. For exampl e,
the PCM must cal cul ate a di fferent i njector pul se
wi dth and i gni ti on ti mi ng for i dl e than i t does for
Wi de Open Throttl e (WOT). There are several di ffer-
ent modes of operati on that determi ne how the PCM
responds to the vari ous i nput si gnal s.
There are two di fferent areas of operati on, OPEN
LOOP and CLOSED LOOP.
Duri ng OPEN LOOP modes the PCM recei ves
i nput si gnal s and responds accordi ng to preset PCM
programmi ng. I nput from the oxygen (O2S) sensor i s
not moni tored duri ng OPEN LOOP modes.
Duri ng CLOSED LOOP modes the PCM does mon-
i tor the O2S sensor i nput. Thi s i nput i ndi cates to the
PCM whether or not the cal cul ated i njector pul se
wi dth resul ts i n the i deal ai r/fuel rati o of 14.7 parts
ai r to 1 part fuel . By moni tori ng the exhaust oxygen
content through the O2S sensor, the PCM can fi ne
tune the i njector pul se wi dth. Fi ne tuni ng i njector
pul se wi dth al l ows the PCM to achi eve opti mum fuel
economy combi ned wi th l ow emi ssi ons.
The mul ti -port fuel i njecti on system has the fol l ow-
i ng modes of operati on:
I gni ti on swi tch ON (zero RPM)
Engi ne start-up
Engi ne warm-up
Crui se (I dl e)
Accel erati on
Decel erati on
Wi de Open Throttl e
I gni ti on swi tch OFF
The engi ne start-up (crank), engi ne warm-up, and
wi de open throttl e modes are OPEN LOOP modes.
Under most operati ng condi ti ons, the accel erati on,
decel erati on, and crui se modes, with the engine at
operating temperature are CLOSED LOOP modes.
IGNITION SWITCH ON (ZERO RPM) MODE
When the mul ti -port fuel i njecti on system i s acti -
vated by the i gni ti on swi tch, the fol l owi ng acti ons
occur:
The PCM determi nes atmospheri c ai r pressure
from the MAP sensor i nput to determi ne basi c fuel
strategy.
The PCM moni tors the cool ant temperature sen-
sor and throttl e posi ti on sensor i nput. The PCM mod-
i fi es fuel strategy based on thi s i nput.
When the key i s i n the ON posi ti on and the engi ne
i s not runni ng (zero rpm), the Automati c Shutdown
(ASD) rel ay and fuel pump rel ay are not energi zed.
Therefore battery vol tage i s not suppl i ed to the fuel
pump, i gni ti on coi l , fuel i njectors or oxygen sensor
heati ng el ement.
ENGINE START-UP MODE
Thi s i s an OPEN LOOP mode. The fol l owi ng
acti ons occur when the starter motor i s engaged.
I f the PCM recei ves the camshaft posi ti on sensor
and crankshaft posi ti on sensor si gnal s, i t energi zes
the ASD rel ay and fuel pump rel ay. These rel ays sup-
pl y battery vol tage to the fuel pump, fuel i njectors,
i gni ti on coi l , and oxygen sensor heati ng el ement. I f
the PCM does not recei ve the camshaft posi ti on sen-
sor and crankshaft posi ti on sensor si gnal s wi thi n
approxi matel y one second, i t de-energi zes the ASD
rel ay and fuel pump rel ay.
The PCM energi zes al l i njectors unti l i t determi nes
crankshaft posi ti on from the camshaft posi ti on sen-
sor and crankshaft posi ti on sensor si gnal s. The PCM
determi nes crankshaft posi ti on wi thi n 1 engi ne revo-
l uti on.
After determi ni ng crankshaft posi ti on, the PCM
begi ns energi zi ng the i njectors i n sequence. The PCM
adjusts i njector pul se wi dth and control s i njector syn-
chroni zati on by turni ng the i ndi vi dual ground paths
to the i njectors On and Off.
When the engi ne i dl es wi thi n 64 RPM of i ts tar-
get RPM, the PCM compares current MAP sensor
val ue wi th the atmospheri c pressure val ue recei ved
duri ng the I gni ti on Swi tch On (zero RPM) mode. I f
the PCM does not detect a mi ni mum di fference
between the two val ues, i t sets a MAP di agnosti c
troubl e code i nto memory.
Once the ASD and fuel pump rel ays have been
energi zed, the PCM:
Determi nes i njector pul se wi dth based on engi ne
cool ant temperature, MAP and the number of engi ne
revol uti ons si nce cranki ng was i ni ti ated.
Moni tors the engi ne cool ant temperature sensor,
camshaft posi ti on sensor, crankshaft posi ti on sensor,
MAP sensor, and throttl e posi ti on sensor to deter-
mi ne correct i gni ti on ti mi ng.
ENGINE WARM-UP MODE
Thi s i s a OPEN LOOP mode. The fol l owi ng i nputs
are recei ved by the PCM:
Engi ne cool ant temperature
Mani fol d absol ute pressure
Engi ne speed (crankshaft posi ti on sensor)
Throttl e posi ti on
A/C swi tch
Battery vol tage
The PCM adjusts i njector pul se wi dth and control s
i njector synchroni zati on by turni ng the i ndi vi dual
ground paths to the i njectors On and Off.
The PCM adjusts i gni ti on ti mi ng and engi ne i dl e
speed. Engi ne i dl e speed i s adjusted through the i dl e
ai r control motor.
CRUISE OR IDLE MODE
Thi s i s a CLOSED LOOP mode. The PCM recog-
ni zes an abrupt i ncrease i n throttl e posi ti on or MAP
pressure as a demand for i ncreased engi ne output
and vehi cl e accel erati on. The PCM i ncreases i njector
pul se wi dth i n response to i ncreased fuel demand.
When the engi ne i s at operati ng temperature thi s
i s a CLOSED LOOP mode. Duri ng crui si ng speed the
fol l owi ng i nputs are recei ved by the PCM:
Exhaust gas oxygen content
A/C control posi ti ons
Battery vol tage
The PCM adjusts i njector pul se wi dth and control s
i njector synchroni zati on by turni ng the i ndi vi dual
ground paths to the i njectors On and Off.
The PCM adjusts engi ne i dl e speed and i gni ti on
ti mi ng. The PCM adjusts the ai r/fuel rati o accordi ng
to the oxygen content i n the exhaust gas.
ACCELERATION MODE
Thi s i s a CLOSED LOOP mode. The PCM recog-
ni zes an abrupt i ncrease i n throttl e posi ti on or MAP
pressure as a demand for i ncreased engi ne output
and vehi cl e accel erati on. The PCM i ncreases i njector
pul se wi dth i n response to i ncreased fuel demand.
DECELERATION MODE
Thi s i s a CLOSED LOOP mode. Duri ng decel era-
ti on the fol l owi ng i nputs are recei ved by the PCM:
Engi ne speed
Exhaust gas oxygen content
A/C control posi ti ons
Battery vol tage
The PCM may recei ve a cl osed throttl e i nput from
the Throttl e Posi ti on Sensor (TPS) when i t senses an
abrupt decrease i n mani fol d pressure. Thi s i ndi cates
a hard decel erati on. The PCM may reduce i njector
pul se wi dth or the number of i njectors fi ri ng per
engi ne revol uti on. Thi s hel ps mai ntai n better control
of the ai r/fuel mi xture (as sensed through the O2S
sensor).
WIDE OPEN THROTTLE (WOT) MODE
Thi s i s an OPEN LOOP mode. Duri ng WOT oper-
ati on, the fol l owi ng i nputs are recei ved by the PCM:
Engi ne speed
When the PCM senses WOT condi ti on through the
Throttl e Posi ti on Sensor (TPS) i t wi l l :
De-energi ze the ai r condi ti oni ng rel ay. Thi s di s-
abl es the ai r condi ti oni ng system.
The exhaust gas oxygen content i nput i s not
accepted by the PCM duri ng WOT operati on. The
PCM wi l l adjust i njector pul se wi dth to suppl y a pre-
determi ned amount of addi ti onal fuel .
IGNITION SWITCH OFF MODE
When the i gni ti on swi tch i s turned to the OFF
posi ti on, the fol l owi ng occurs:
Al l outputs are turned off.
No i nputs are moni tored.
The PCM shuts down.
SYSTEM DIAGNOSIS
The PCM can test many of i ts own i nput and out-
put ci rcui ts. I f the PCM senses a faul t i n a major
system, the PCM stores a Di agnosti c Troubl e Code
(DTC) i n memory.
For DTC i nformati on, refer to Group 25, Emi ssi on
Control Systems. See On-Board Di agnosti cs.
CCD BUS
Vari ous control l ers and modul es exchange i nforma-
ti on through a communi cati ons port cal l ed the CCD
Bus. The PCM transmi ts the mal functi on i ndi cator
(check engi ne) l amp On/Off si gnal , engi ne RPM and
vehi cl e l oad i nformati on on the CCD Bus.
POWERTRAIN CONTROL MODULE (PCM)
The PCM i s a di gi tal computer contai ni ng a mi cro-
processor (Fi g. 1). The PCM recei ves i nput si gnal s
from vari ous swi tches and sensors that are referred
to as PCM I nputs. Based on these i nputs, the PCM
adjusts vari ous engi ne and vehi cl e operati ons
through devi ces that are referred to as PCM Out-
puts.
PCM Inputs:
Ai r Condi ti oni ng Head Pressure
Battery Vol tage
Brake Swi tch
Camshaft Posi ti on Sensor
Crankshaft Posi ti on Sensor
Heated Oxygen Sensors (Upstream and Down-
stream)
I ntake Ai r Temperature Sensor (2.4L onl y)
Knock Sensor (execpt 3.0L)
Mani fol d Absol ute Pressure (MAP) Sensor
SCI Recei ve
Speed Control System Control s
Throttl e Posi ti on Sensor
Transaxl e Park/Neutral Posi ti on Swi tch (auto-
mati c transaxl e)
Transmi ssi on Control Modul e
Vehi cl e Speed Sensor
PCM Outputs:
Ai r Condi ti oni ng Cl utch Rel ay
Automati c Shutdown (ASD) Rel ay
Data Li nk Connector
Proporti onal Purge Sol enoi d
El ectri c EGR Transducer
Fuel I njectors
Fuel Pump Rel ay
Generator Fi el d
I dl e Ai r Control Motor
I gni ti on Coi l
Leak Detecti on Pump
Mal functi on I ndi cator (Check Engi ne) Lamp
Radi ator Fan Control Modul e
Speed Control Sol enoi ds
Tachometer Output
Torque Converter Cl utch Sol enoi d (3 speed
transmi ssi on)
Transmi ssi on Control Modul e
Based on i nputs i t recei ves, the PCM adjusts fuel
i njector pul se wi dth, i dl e speed, i gni ti on spark
advance, i gni ti on coi l dwel l and cani ster purge oper-
ati on. The PCM regul ates the cool i ng fan, ai r condi -
ti oni ng and speed control systems. The PCM changes
generator charge rate by adjusti ng the generator
fi el d.
The PCM adjusts i njector pul se wi dth (ai r/fuel
rati o) based on the fol l owi ng i nputs:
Battery vol tage
Exhaust gas content (oxygen sensors)
The PCM adjusts i gni ti on ti mi ng based on the fol -
l owi ng i nputs.
Barometri c pressure
Fig. 1 Powertrain Control Module (PCM)
I ntake ai r temperature (2.4L onl y)
Transaxl e gear sel ecti on (park/neutral swi tch)
The PCM al so adjusts engi ne i dl e speed through
the i dl e ai r control motor based on the fol l owi ng
i nputs.
Ai r condi ti oni ng sel ect swi tch head pressure
Brake swi tch
Transaxl e gear sel ecti on (park/neutral swi tch)
Vehi cl e di stance (speed)
The Automati c Shutdown (ASD) and fuel pump
rel ays are l ocated i n the Power Di stri buti on Center
(PDC).
The camshaft posi ti on sensor (di stri butor pi ck-up
si gnal 3.0L) and crankshaft posi ti on sensor si gnal s
are sent to the PCM. I f the PCM does not recei ve
both si gnal s wi thi n approxi matel y one second of
engi ne cranki ng, i t deacti vates the ASD rel ay and
fuel pump rel ay. When these rel ays are deacti vated,
power i s shut off to the fuel i njectors, i gni ti on coi l ,
oxygen sensor heati ng el ement and fuel pump.
The PCM contai ns a vol tage converter that
changes battery vol tage to a regul ated 8.0 vol ts to
power the camshaft posi ti on sensor, crankshaft posi -
ti on sensor and vehi cl e speed sensor. The PCM al so
provi des a 5.0 vol t suppl y for the mani fol d absol ute
pressure sensor, throttl e posi ti on sensor and engi ne
cool ant temperature sensor.
AIR CONDITIONING PRESSURE TRANSDUCER
PCM INPUT
the A/C compressor di scharge (hi gh si de) pressure
through the ai r condi ti oni ng pressure transducer.
The transducer suppl i es an i nput to the PCM. The
PCM engages the A/C compressor cl utch i f pressure
i s suffi ci ent for A/C system operati on.
AIR CONDITIONING SWITCH SENSEPCM INPUT
When the ai r condi ti oni ng or defrost swi tch i s put
i n the ON posi ti on and the l ow pressure swi tch, com-
bi nati on val ve, and hi gh pressure swi tch cl ose, the
PCM recei ves an A/C i nput. After recei vi ng thi s
i nput, the PCM acti vates the A/C compressor cl utch
by groundi ng the A/C cl utch rel ay. The PCM al so
adjusts i dl e speed to a schedul ed RPM to compensate
for i ncreased engi ne l oad.
AUTOMATIC SHUTDOWN (ASD) SENSEPCM
INPUT
The ASD sense ci rcui t i nforms the PCM when the
ASD rel ay energi zes. A 12 vol t si gnal at thi s i nput
i ndi cates to the PCM that the ASD has been acti -
vated. Thi s i nput i s used onl y to sense that the ASD
rel ay i s energi zed.
When energi zed, the ASD rel ay suppl i es battery
vol tage to the fuel i njectors, i gni ti on coi l s and the
heati ng el ement i n each oxygen sensor. I f the PCM
does not recei ve 12 vol ts from thi s i nput after
groundi ng the ASD rel ay, i t sets a Di agnosti c Troubl e
Code (DTC).
BATTERY VOLTAGEPCM INPUT
The PCM moni tors the battery vol tage i nput to
determi ne fuel i njector pul se wi dth and generator
fi el d control .
I f battery vol tage i s l ow the PCM wi l l i ncrease
i njector pul se wi dth (peri od of ti me that the i njector
i s energi zed).
BRAKE SWITCHPCM INPUT
When the brake swi tch i s acti vated, the PCM
recei ves an i nput i ndi cati ng that the brakes are
bei ng appl i ed. After recei vi ng thi s i nput the PCM
mai ntai ns i dl e speed to a schedul ed RPM through
control of the i dl e ai r control motor. The brake swi tch
i s mounted on the brake pedal support bracket.
CAMSHAFT POSITION SENSORPCM INPUT
3.3/3.8L
The sensor generates pul ses as groups of notches
on the camshaft sprocket pass underneath i t (Fi g. 2).
The PCM keeps track of crankshaft rotati on and
i denti fi es each cyl i nder by the pul ses generated by
the notches on the camshaft sprocket. Four crank-
shaft pul ses fol l ow each group of camshaft pul ses.
When the PCM recei ves two camshaft pul ses fol -
l owed by the l ong fl at spot on the camshaft sprocket,
i t knows that the crankshaft ti mi ng marks for cyl i n-
der one are next (on dri vepl ate). When the PCM
recei ves one camshaft pul se after the l ong fl at spot
on the sprocket, cyl i nder number two crankshaft ti m-
i ng marks are next. After 3 camshaft pul ses, the
PCM knows cyl i nder four crankshaft ti mi ng marks
fol l ow. One camshaft pul se after the three pul ses
i ndi cates cyl i nder fi ve. The two camshaft pul ses after
cyl i nder 5 si gnal s cyl i nder si x (Fi g. 3). The PCM can
synchroni ze on cyl i nders 1 or 4.
When metal al i gns wi th the sensor, vol tage goes
l ow (l ess than 0.5 vol ts). When a notch al i gns wi th
the sensor, vol tage spi kes hi gh (5.0 vol ts). As a group
of notches pass under the sensor, the vol tage
swi tches from l ow (metal ) to hi gh (notch) then back
to l ow. The number of notches determi ne the amount
of pul ses. I f avai l abl e, an osci l l oscope can di spl ay the
square wave patterns of each ti mi ng events.
Top dead center (TDC) does not occur when
notches on the camshaft sprocket pass bel ow the cyl -
i nder. TDC occurs after the camshaft pul se (or
pul ses) and after the 4 crankshaft pul ses associ ated
wi th the parti cul ar cyl i nder. The arrows and cyl i nder
cal l outs on Fi gure 4 represent whi ch cyl i nder the
fl at spot and notches i denti fy, they do not i ndi cate
TDC posi ti on.
The camshaft posi ti on sensor i s mounted to the top
of the ti mi ng case cover (Fi g. 4). The bottom of the
sensor i s posi ti oned above the camshaft sprocket.
The distance between the bottom of sensor and
the camshaft sprocket is critical to the opera-
tion of the system. When servicing the camshaft
position sensor, refer to the 3.3L and 3.8L Multi-
Port Fuel InjectionService Procedures sec-
tion in this Group.
2.4L
The camshaft posi ti on sensor attaches to the rear
of the cyl i nder head (Fi g. 5). A target magnet
attaches to the rear of the camshaft and i ndexes to
the correct posi ti on (Fi g. 6). The target magnet has
four di fferent pol es arranged i n an asymmetri cal pat-
tern. As the target magnet rotates, the camshaft
posi ti on sensor senses the change i n pol ari ty (Fi g. 7).
The sensor output swi tch swi tches from hi gh (5.0
vol ts) to l ow (0.30 vol ts) as the target magnet rotates.
When the north pol e of the target magnet passes
under the sensor, the output swi tches hi gh. The sen-
sor output swi tches l ow when the south pol e of the
target magnet passes underneath.
Fig. 3 Camshaft Sprocket
CRANKSHAFT POSITION SENSORPCM INPUT
3.0/3.3/3.8L
The crankshaft posi ti on sensor (Fi g. 8) senses sl ots
cut i nto the transaxl e dri vepl ate extensi on. There are
3 sets of sl ots. Each set contai ns 4 sl ots, for a total of
12 sl ots (Fi g. 9). Basi c ti mi ng i s set by the posi ti on of
the l ast sl ot i n each group. Once the PCM senses the
l ast sl ot, i t determi nes crankshaft posi ti on (whi ch
pi ston wi l l next be at TDC) from the camshaft posi -
ti on sensor i nput. I t may take the PCM one engi ne
revol uti on to determi ne crankshaft posi ti on.
The PCM uses the crankshaft posi ti on sensor si g-
nal to determi ne i njector sequence, i gni ti on ti mi ng
and presence of mi sfi re. Once crankshaft posi ti on has
been determi ned, the PCM begi ns energi zi ng the
i njectors i n sequence.
Fig. 7 Target Magnet Polarity
Fig. 9 Timing Slots
The crankshaft posi ti on sensor i s l ocated i n the
transaxl e housi ng, above the vehi cl e speed sensor
(Fi g. 10). The bottom of the sensor i s posi ti oned next
to the dri ve pl ate. The distance between the bot-
tom of sensor and the drive plate is critical to
the operation of the system. When servicing the
crankshaft position sensor, refer to the appro-
priate Multi-Port Fuel Injection Service Proce-
dures section in this Group.
2.4L
The second crankshaft counterwei ght has
machi ned i nto i t two sets of four ti mi ng reference
notches and a 60 degree si gnature notch (Fi g. 11).
From the crankshaft posi ti on sensor i nput the PCM
determi nes engi ne speed and crankshaft angl e (posi -
ti on).
The notches generate pul ses from hi gh to l ow i n
the crankshaft posi ti on sensor output vol tage. When
a metal porti on of the counterwei ght al i gns wi th the
crankshaft posi ti on sensor, the sensor output vol tage
goes l ow (l ess than 0.3 vol ts). When a notch al i gns
wi th the sensor, vol tage spi kes hi gh (5.0 vol ts). As a
group of notches pass under the sensor, the output
vol tage swi tches from l ow (metal ) to hi gh (notch)
then back to l ow.
I f avai l abl e, an osci l l oscope can di spl ay the square
wave patterns of each vol tage pul se. From the wi dth
of the output vol tage pul ses, the PCM cal cul ates
engi ne speed. The wi dth of the pul ses represent the
amount of ti me the output vol tage stays hi gh before
swi tchi ng back to l ow. The peri od of ti me the sensor
output vol tage stays hi gh before swi tchi ng back to
l ow i s referred to as pul se wi dth. The faster the
engi ne i s operati ng, the smal l er the pul se wi dth on
the osci l l oscope.
By counti ng the pul ses and referenci ng the pul se
from the 60 degree si gnature notch, the PCM cal cu-
l ates crankshaft angl e (posi ti on). I n each group of
ti mi ng reference notches, the fi rst notch represents
69 degrees before top dead center (BTDC). The sec-
ond notch represents 49 degrees BTDC. The thi rd
notch represents 29 degrees. The l ast notch i n each
set represents 9 degrees before top dead center
(TDC).
The ti mi ng reference notches are machi ned to a
uni form wi dth representi ng 13.6 degrees of crank-
shaft rotati on. From the vol tage pul se wi dth the
PCM tel l s the di fference between the ti mi ng refer-
ence notches and the 60 degree si gnature notch. The
60 degree si gnature notch produces a l onger pul se
wi dth than the smal l er ti mi ng reference notches. I f
the camshaft posi ti on sensor i nput swi tches from
hi gh to l ow when the 60 degree si gnature notch
passes under the crankshaft posi ti on sensor, the
PCM knows cyl i nder number one i s the next cyl i nder
at TDC.
engi ne bl ock behi nd the generator, just above the oi l
fi l ter (Fi g. 12).
ENGINE COOLANT TEMPERATURE SENSORPCM
INPUT
The engi ne cool ant temperature sensor i s a vari -
abl e resi stor wi th a range of -40C to 129C (-40F to
265F).
The engi ne cool ant temperature sensor provi des an
i nput vol tage to the PCM. As cool ant temperature
vari es, the sensor resi stance changes resul ti ng i n a
di fferent i nput vol tage to the PCM.
When the engi ne i s col d, the PCM wi l l demand
sl i ghtl y ri cher ai r/fuel mi xtures and hi gher i dl e
speeds unti l normal operati ng temperatures are
reached.
The engi ne cool ant sensor i s al so used for cool i ng
fan control .
Fig. 10 Crankshaft Position Sensor Location3.0/
3.3/3.8L
Fig. 11 Timing Reference Notches
3.0/3.3/3.8L
housi ng (Fi g. 13) and (Fi g. 14).
2.4L
HEATED OXYGEN SENSOR (O2S SENSOR)PCM
INPUT
The O2S produce vol tages from 0 to 1 vol t, depend-
i ng upon the oxygen content of the exhaust gas i n
the exhaust mani fol d. When a l arge amount of oxy-
gen i s present (caused by a l ean ai r/fuel mi xture), the
sensors produces a l ow vol tage. When there i s a
l esser amount present (ri ch ai r/fuel mi xture) i t pro-
duces a hi gher vol tage. By moni tori ng the oxygen
content and converti ng i t to el ectri cal vol tage, the
sensors act as a ri ch- l ean swi tch.
The oxygen sensors are equi pped wi th a heati ng
el ement that keeps the sensors at proper operati ng
temperature duri ng al l operati ng modes. Mai ntai ni ng
correct sensor temperature at al l ti mes al l ows the
Fig. 12 Crankshaft Position Sensor2.4L
3.8L
system to enter i nto cl osed l oop operati on sooner.
Al so, i t al l ows the system to remai n i n cl osed l oop
operati on duri ng peri ods of extended i dl e.
I n Cl osed Loop operati on the PCM moni tors the
O2S i nput (al ong wi th other i nputs) and adjusts the
i njector pul se wi dth accordi ngl y. Duri ng Open Loop
operati on the PCM i gnores the O2 sensor i nput. The
PCM adjusts i njector pul se wi dth based on prepro-
grammed (fi xed) val ues and i nputs from other sen-
sors.
The Automati c Shutdown (ASD) rel ay suppl i es bat-
tery vol tage to both the upstream and downstream
heated oxygen sensors. The oxygen sensors are
equi pped wi th a heati ng el ement. The heati ng el e-
ments reduce the ti me requi red for the sensors to
reach operati ng temperature.
UPSTREAM HEATED OXYGEN SENSOR
The upstream O2S i s l ocated i n the exhaust mani -
fol d and provi des an i nput vol tage to the PCM. The
i nput tel l s the PCM the oxygen content of the
exhaust gas (Fi g. 16) or (Fi g. 17) or (Fi g. 18). The
PCM uses thi s i nformati on to fi ne tune the ai r/fuel
rati o by adjusti ng i njector pul se wi dth.
DOWNSTREAM HEATED OXYGEN SENSOR
The downstream heated oxygen sensor threads i nto
the outl et pi pe at the rear of the catal yti c convertor
(Fi g. 19). The downstream heated oxygen sensor
i nput i s used to detect catal yti c convertor deteri ora-
ti on. As the convertor deteri orates, the i nput from
the downstream sensor begi ns to match the upstream
sensor i nput except for a sl i ght ti me del ay. By com-
pari ng the downstream heated oxygen sensor i nput
to the i nput from the upstream sensor, the PCM cal -
cul ates catal yti c convertor effi ci ency.
When the catal yti c converter effi ci ency drops bel ow
emi ssi on standards, the PCM stores a di agnosti c
troubl e code and i l l umi nates the Mal functi on I ndi ca-
tor Lamp (MI L). For more i nformati on, refer to
Group 25 - Emi ssi on Control Systems.
KNOCK SENSORPCM INPUT
The knock sensor i s onl y on the 2.4/3.3/3.8L
engi nes, not used on the 3.0L engi ne.
i nder bl ock i n front of the starter (Fi g. 20) or (Fi g.
21). When the knock sensor detects a knock i n one of
the cyl i nders, i t sends an i nput si gnal to the PCM. I n
response, the PCM retards i gni ti on ti mi ng for al l cyl -
i nders by a schedul ed amount.
Knock sensors contai n a pi ezoel ectri c materi al
whi ch sends an i nput vol tage (si gnal ) to the PCM. As
the i ntensi ty of the engi ne knock vi brati on i ncreases,
the knock sensor output vol tage al so i ncreases.
Fig. 16 Heated Oxygen Sensor2.4L Engine
Fig. 17 Heated Oxygen Sensor3.0L Engine
Fig. 18 Heated Oxygen Sensor3.3/3.8L Engine
SENSORPCM INPUT
The PCM suppl i es 5 vol ts to the MAP sensor. The
MAP sensor converts i ntake mani fol d pressure i nto
vol tage. The PCM moni tors the MAP sensor output
vol tage. As vacuum i ncreases, MAP sensor vol tage
decreases proporti onatel y. Al so, as vacuum decreases,
MAP sensor vol tage i ncreases proporti onatel y.
Duri ng cranki ng, before the engi ne starts runni ng,
the PCM determi nes atmospheri c ai r pressure from
the MAP sensor vol tage. Whi l e the engi ne operates,
the PCM determi nes i ntake mani fol d pressure from
the MAP sensor vol tage.
Based on MAP sensor vol tage and i nputs from
other sensors, the PCM adjusts spark advance and
the ai r/fuel mi xture.
The MAP sensor (Fi g. 22) or (Fi g. 23) or (Fi g. 24)
mounts to the i ntake mani fol d near the throttl e body
i nl et to the mani fol d. The sensor connects el ectri cal l y
to the PCM.
SPEED CONTROLPCM INPUT
The speed control system provi des fi ve separate
vol tages (i nputs) to the Powertrai n Control Modul e
(PCM). The vol tages correspond to the ON/OFF, SET,
RESUME and CANCEL.
The speed control ON vol tage i nforms the PCM
that the speed control system has been acti vated.
The speed control SET vol tage i nforms the PCM that
Fig. 19 Downstream Heated Oxygen Sensor
Fig. 20 Knock Sensor3.3/3.8L Engines
Fig. 21 Knock Sensor2.4L Engine
Fig. 22 MAP Sensor3.3/3.8L
a fi xed vehi cl e speed has been sel ected. The speed
control RESUME vol tage i ndi cates the previ ous fi xed
speed i s requested. The speed control CANCEL vol t-
age tel l s the PCM to deacti vate but retai n set speed
i n memory (same as depressi ng the brake pedal ). The
speed control OFF vol tage tel l s the PCM that the
speed control system has deacti vated. Refer to Group
8H for more speed control i nformati on.
TRANSAXLE PARK/NEUTRAL SWITCHPCM
INPUT
The park/neutral swi tch i s l ocated on the transaxl e
housi ng (Fi g. 25). I t provi des an i nput to the PCM
i ndi cati ng whether the automati c transaxl e i s i n
Park or Neutral . Thi s i nput i s used to determi ne i dl e
speed (varyi ng wi th gear sel ecti on) and i gni ti on ti m-
i ng advance. The park neutral swi tch i s someti mes
referred to as the neutral safety swi tch.
THROTTLE POSITION SENSOR (TPS)PCM INPUT
The TPS i s mounted on the throttl e body and con-
nected to the throttl e bl ade shaft (Fi g. 26) or (Fi g.
27) or (Fi g. 28). The TPS i s a vari abl e resi stor that
provi des the (PCM) wi th an i nput si gnal (vol tage)
representi ng throttl e bl ade posi ti on. As the posi ti on
of the throttl e bl ade changes, the resi stance of the
TPS changes.
Fig. 23 MAP Sensor3.0L
Fig. 24 MAP Sensor2.4L
Fig. 25 Park Neutral Switch4-Speed Electronic
Automatic TransaxleTypical
Fig. 26 Throttle Position Sensor3.3/3.8L
The PCM suppl i es approxi matel y 5 vol ts to the
TPS. The TPS output vol tage (i nput si gnal to the
PCM) represents the throttl e bl ade posi ti on. The TPS
output vol tage to the PCM vari es from approxi matel y
0.5 vol t at mi ni mum throttl e openi ng (i dl e) to 4 vol ts
at wi de open throttl e. Al ong wi th i nputs from other
sensors, the PCM uses the TPS i nput to determi ne
current engi ne operati ng condi ti ons and adjust fuel
i njector pul se wi dth and i gni ti on ti mi ng.
VEHICLE SPEED AND DISTANCEPCM INPUT
The transaxl e output speed sensor suppl i es the
vehi cl e speed and di stance i nputs to the PCM. The
output speed sensor i s l ocated on the si de of the tran-
saxl e (Fi g. 25).
The speed and di stance si gnal s, al ong wi th a cl osed
throttl e si gnal from the TPS, determi ne i f a cl osed
throttl e decel erati on or normal i dl e condi ti on (vehi cl e
stopped) exi sts. Under decel erati on condi ti ons, the
PCM adjusts the i dl e ai r control motor to mai ntai n a
desi red MAP val ue. Under i dl e condi ti ons, the PCM
adjusts the i dl e ai r control motor to mai ntai n a
desi red engi ne speed.
INTAKE AIR TEMPERATURE SENSORPCM INPUT
(2. 4L ONLY)
The I ntake Ai r Temperature (I AT) sensor measures
the temperature of the i ntake ai r as i t enters the
engi ne. The sensor suppl i es one of the i nputs the
PCM uses to determi ne i njector pul se wi dth and
spark advance.
The I AT sensor threads i nto the i ntake mani fol d
(Fi g. 29).
AIR CONDITIONING (A/C) CLUTCH RELAYPCM
OUTPUT
The PCM operates the ai r condi ti oni ng cl utch rel ay
ground ci rcui t. The radi ator fan control modul e sup-
pl i es battery power to the sol enoi d si de of the rel ay.
The ai r condi ti oni ng cl utch rel ay wi l l not energi ze
unl ess the radi ator fan control modul e energi zes. The
radi ator control modul e energi zes when the ai r con-
di ti oni ng or defrost swi tch i s put i n the ON posi ti on
and the l ow pressure swi tch, combi nati on val ve, and
hi gh pressure swi tch cl ose.
Wi th the engi ne operati ng, the PCM cycl es the ai r
condi ti oni ng cl utch on and off when the A/C swi tch
cl oses wi th the bl ower motor swi tch i n the On posi -
ti on. When the PCM senses l ow i dl e speeds or wi de-
open-throttl e through the throttl e posi ti on sensor, i t
de-energi zes the A/C cl utch rel ay. The rel ay contacts
open, preventi ng ai r condi ti oni ng cl utch engagement.
The ai r condi ti oni ng cl utch rel ay i s l ocated i n the
Power Di stri buti on Center (PDC). The PDC i s l ocated
Fig. 27 Throttle Position Sensor3.0L
Fig. 28 Throttle Position Sensor2.4L
i n the engi ne compartment next to the battery (Fi g.
30). A l abel affi xed to the undersi de of the PDC cover
i denti fi es the rel ays and fuses i n the PDC.
GENERATOR FIELDPCM OUTPUT
The PCM regul ates the chargi ng system vol tage
wi thi n a range of 12.9 to 15.0 vol ts. Refer to Group
8A for Battery system i nformati on and 8C for charg-
i ng system i nformati on.
AUTOMATIC SHUTDOWN RELAYPCM OUTPUT
tery vol tage to the fuel i njectors, el ectroni c i gni ti on
coi l and the heati ng el ements i n the oxygen sensors.
A buss bar i n the Power Di stri buti on Center (PDC)
suppl i es vol tage to the sol enoi d si de and contact si de
of the rel ay. The ASD rel ay power ci rcui t contai ns a
25 amp fuse between the buss bar i n the PDC and
the rel ay. The fuse i s l ocated i n the PDC. Refer to
Group 8W, Wi ri ng Di agrams for ci rcui t i nformati on.
The PCM control s the rel ay by swi tchi ng the
ground path for the sol enoi d si de of the rel ay on and
off. The PCM turns the ground path off when the
i gni ti on swi tch i s i n the Off posi ti on unl ess the 02
Heater Moni tor test i s bei ng run. Refer to Group 25,
On-Board Di agnosti cs. When the i gni ti on swi tch i s i n
the On or Crank posi ti on, the PCM moni tors the
sor si gnal s to determi ne engi ne speed and i gni ti on
ti mi ng (coi l dwel l ). I f the PCM does not recei ve the
sor si gnal s when the i gni ti on swi tch i s i n the Run
posi ti on, i t wi l l de-energi ze the ASD rel ay.
The ASD rel ay i s l ocated i n the PDC (Fi g. 30). A
l abel affi xed to the undersi de of the PDC cover i den-
ti fi es the rel ays and fuses i n the PDC.
FUEL PUMP RELAYPCM OUTPUT
The fuel pump rel ay suppl i es battery vol tage to the
fuel pump. The fuel pump rel ay power ci rcui t con-
tai ns a 9 amp fuse. The fuse i s l ocated i n the PDC.
Refer to Group 8W, Wi ri ng Di agrams for ci rcui t i nfor-
mati on.
The PCM control s the fuel pump rel ay by swi tch-
i ng the ground path for the sol enoi d si de of the rel ay
on and off. The PCM turns the ground path off when
the i gni ti on swi tch i s i n the Off posi ti on. When the
i gni ti on swi tch i s i n the On posi ti on, the PCM ener-
gi zes the fuel pump. I f the crankshaft posi ti on sensor
does not detect engi ne rotati on, the PCM de-ener-
gi zes the rel ay after approxi matel y one second.
The fuel pump rel ay i s l ocated i n the PDC (Fi g.
30). A l abel affi xed to the undersi de of the PDC cover
i denti fi es the rel ays and fuses i n the PDC.
STARTER RELAYPCM OUTPUT
Doubl e Start Overri de i a a feature that prevents
the starter from operati ng i f the engi ne i s al ready
runni ng. Thi s feature i s accompl i shed wi th software
onl y. There was no hardware added because of thi s
feature. To i ncorporate the uni que feature of Doubl e
Start Overri de, i t was necessary to use the PCM
(software) to control the starter ci rcui t. To use the
PCM i t was necessary to separate the starter rel ay
coi l ground from the park neutral swi tch. The starter
rel ay ground i s now control l ed through Pi n 60 of the
PCM. Thi s al l ows the PCM to i nterrupt the ground
ci rcui t i f other i nputs tel l i t that the engi ne i s turn-
i ng. I f the starter system i s operati ng properl y, i t can
be assumed that the overri de protecti on i s al so work-
i ng.
IDLE AIR CONTROL MOTORPCM OUTPUT
The i dl e ai r control motor i s mounted on the throt-
tl e body. The PCM operates the i dl e ai r control motor
(Fi g. 26) or (Fi g. 27) or (Fi g. 28). The PCM adjusts
engi ne i dl e speed through the i dl e ai r control motor
to compensate for engi ne l oad or ambi ent condi ti ons.
The throttl e body has an ai r bypass passage that
provi des ai r for the engi ne at i dl e (the throttl e bl ade
i s cl osed). The i dl e ai r control motor pi ntl e protrudes
i nto the ai r bypass passage and regul ates ai r fl ow
through i t.
The PCM adjusts engi ne i dl e speed by movi ng the
i dl e ai r control motor pi ntl e i n and out of the bypass
passage. The adjustments are based on i nputs the
PCM recei ves. The i nputs are from the throttl e posi -
ti on sensor, crankshaft posi ti on sensor, cool ant tem-
perature sensor, and vari ous swi tch operati ons
Fig. 30 Power Distribution Center (PDC)
(brake, park/neutral , ai r condi ti oni ng). Decel erati on
di e out i s al so prevented by i ncreasi ng ai rfl ow when
the throttl e i s cl osed qui ckl y after a dri vi ng (speed)
condi ti on.
DUTY CYCLE EVAP CANISTER PURGE
SOLENOIDPCM OUTPUT
The duty cycl e EVAP purge sol enoi d regul ates the
rate of vapor fl ow from the EVAP cani ster to the
throttl e body. The PCM operates the sol enoi d.
Duri ng the col d start warm-up peri od and the hot
start ti me del ay, the PCM does not energi ze the sol e-
noi d. When de-energi zed, no vapors are purged. The
PCM de-energi zes the sol enoi d duri ng open l oop oper-
ati on.
The engi ne enters cl osed l oop operati on after i t
reaches a speci fi ed temperature and the ti me del ay
ends. Duri ng cl osed l oop operati on, the PCM ener-
gi zes and de-energi zes the sol enoi d 5 or 10 ti mes per
second, dependi ng upon operati ng condi ti ons. The
PCM vari es the vapor fl ow rate by changi ng sol enoi d
pul se wi dth. Pul se wi dth i s the amount of ti me the
sol enoi d energi zes.
A rubber boot covers the duty cycl e EVAP purge
sol enoi d. The sol enoi d attaches to a bracket mounted
to the ri ght engi ne mount (Fi g. 31). The top of the
sol enoi d has the word TOP on i t. The sol enoi d wi l l
not operate properl y unl ess i t i s i nstal l ed correctl y.
PROPORTIONAL PURGE SOLENOID
Al l vehi cl es use a proporti onal purge sol enoi d. The
sol enoi d regul ates the rate of vapor fl ow from the
EVAP cani ster to the throttl e body. The PCM oper-
ates the sol enoi d.
noi d. When de-energi zed, no vapors are purged.
The proporti onal purge sol enoi d operates at a fre-
quency of 200 hz and i s control l ed by an engi ne con-
trol l er ci rcui t that senses the current bei ng appl i ed
to the proporti onal purge sol enoi d and then adjusts
that current to achi eve the desi red purge fl ow. The
proporti onal purge sol enoi d control s the purge rate of
fuel vapors from the vapor cani ster and fuel tank to
the engi ne i ntake mani fol d.
ELECTRONIC EGR TRANSDUCER SOLENOIDPCM
OUTPUT
The el ectroni c EGR transducer contai ns an el ectri -
cal l y operated sol enoi d and a back-pressure trans-
ducer (Fi g. 33) or (Fi g. 34) or (Fi g. 35). The PCM
operates the sol enoi d. The PCM determi nes when to
energi ze the sol enoi d. Exhaust system back-pressure
control s the transducer.
When the PCM energi zes the sol enoi d, vacuum
does not reach the transducer. Vacuum fl ows to the
transducer when the PCM de-energi zes the sol enoi d.
When exhaust system back-pressure becomes hi gh
enough, i t ful l y cl oses a bl eed val ve i n the trans-
ducer. When the PCM de-energi zes the sol enoi d and
back-pressure cl oses the transducer bl eed val ve, vac-
uum fl ows through the transducer to operate the
EGR val ve.
De-energi zi ng the sol enoi d, but not ful l y cl osi ng the
transducer bl eed hol e (because of l ow back-pressure),
vari es the strength of vacuum appl i ed to the EGR
val ve. Varyi ng the strength of the vacuum changes
the amount of EGR suppl i ed to the engi ne. Thi s pro-
Fig. 31 Duty Cycle EVAP Purge Solenoid
Fig. 32 Proportional Purge Solenoid
vi des the correct amount of exhaust gas reci rcul ati on
for di fferent operati ng condi ti ons.
DATA LINK CONNECTORPCM OUTPUT
The data l i nk connector provi des the techni ci an
wi th the means to connect the DRB scan tool to di ag-
nosi s the vehi cl e. The connector i s l ocated under the
dash (Fi g. 36).
AUTOMATIC TRANSAXLE CONTROL MODULE
PCM OUTPUT
The el ectroni c automati c transaxl e control modul e
and the PCM suppl y i nformati on to each other
through the CCD Bus. The i nformati on i ncl udes
engi ne speed and vehi cl e l oad. The PCM uses the
i nformati on when adjusti ng the fuel and i gni ti on
strategy.
FUEL INJECTORSPCM OUTPUT
The fuel i njectors are 12 ohm el ectri cal sol enoi ds
(Fi g. 37). The i njector contai ns a pi ntl e that cl oses off
an ori fi ce at the nozzl e end. When el ectri c current i s
suppl i ed to the i njector, the armature and needl e
move a short di stance agai nst a spri ng, al l owi ng fuel
to fl ow out the ori fi ce. Because the fuel i s under hi gh
pressure, a fi ne spray i s devel oped i n the shape of a
hol l ow cone. The sprayi ng acti on atomi zes the fuel ,
addi ng i t to the ai r enteri ng the combusti on chamber.
The i njectors are posi ti oned i n the i ntake mani fol d.
Fig. 33 EGR Solenoid3.3/3.8L
Fig. 34 EGR Solenoid3.0L
Fig. 35 EGR Solenoid2.4L
Fig. 36 Data Link Connector
The i njectors are posi ti oned i n the i ntake mani fol d
wi th the nozzl e ends di rectl y above the i ntake val ve
port (Fi g. 38).
The fuel i njectors are operated by the PCM. They
are energi zed i n a sequenti al order duri ng al l engi ne
operati ng condi ti ons except start up. The PCM i ni -
ti al l y energi zes al l i njectors at the same ti me. Once
PCM determi nes crankshaft posi ti on, i t begi ns ener-
gi zi ng the i njectors i n sequence.
tery vol tage to the i njectors. The PCM provi des the
ground path for the i njectors. By swi tchi ng the
ground path on and off, the PCM adjusts i njector
pul se wi dth. Pul se wi dth i s the amount of ti me the
i njector i s energi zed. The PCM adjusts i njector pul se
wi dth based on i nputs i t recei ves.
IGNITION COILPCM OUTPUT
The coi l assembl y consi sts of i ndependent coi l s
mol ded together (Fi g. 39) or (Fi g. 40) or (Fi g. 41).
The coi l assembl y i s mounted on the i ntake mani fol d.
Hi gh tensi on l eads route to each cyl i nder from the
coi l . The coi l fi res two spark pl ugs every power
stroke. One pl ug i s the cyl i nder under compressi on,
the other cyl i nder fi res on the exhaust stroke. The
PCM determi nes whi ch of the coi l s to charge and fi re
at the correct ti me.
The Automati c Shutdown (ASD) rel ay provi des bat-
tery vol tage to the i gni ti on coi l . The PCM provi des a
ground contact (ci rcui t) for energi zi ng the coi l . When
the PCM breaks the contact, the energy i n the coi l
pri mary transfers to the secondary causi ng the
spark. The PCM wi l l de-energi ze the ASD rel ay i f i t
does not recei ve the crankshaft posi ti on sensor and
camshaft posi ti on sensor i nputs. Refer to Automati c
Fig. 38 Fuel Injector LocationTypical
Fig. 39 Ignition Coil2.4L
Fig. 40 Ignition Coil3.0L
Shutdown (ASD) Rel ayPCM Output i n thi s secti on
for rel ay operati on.
TORQUE CONVERTER CLUTCH SOLENOIDPCM
OUTPUT
Three-speed automati c transaxl es use a torque con-
verter cl utch sol enoi d. The PCM control s the engage-
ment of the torque converter cl utch through the
sol enoi d. The torque converter cl utch i s engaged onl y
i n di rect dri ve mode. Refer to Group 21 for transaxl e
i nformati on.
LAMPPCM OUTPUT
The PCM suppl i es the mal functi on i ndi cator (check
engi ne) l amp on/off si gnal to the i nstrument panel
through the CCD Bus. The CCD Bus i s a communi -
cati ons port. Vari ous modul es use the CCD Bus to
exchange i nformati on.
The Check Engi ne l amp comes on each ti me the
i gni ti on key i s turned ON and stays on for 3 seconds
as a bul b test.
The Mal functi on I ndi cator Lamp (MI L) stays on
conti nuousl y, when the PCM has entered a Li mp-I n
mode or i denti fi ed a fai l ed emi ssi on component. Dur-
i ng Li mp-i n Mode, the PCM attempts to keep the
system operati onal . The MI L si gnal s the need for
i mmedi ate servi ce. I n l i mp-i n mode, the PCM com-
pensates for the fai l ure of certai n components that
send i ncorrect si gnal s. The PCM substi tutes for the
i ncorrect si gnal s wi th i nputs from other sensors.
I f the PCM detects acti ve engi ne mi sfi re severe
enough to cause catal yst damage, i t fl ashes the MI L.
At the same ti me the PCM al so sets a Di agnosti c
Troubl e Code (DTC).
For signals that can trigger the MIL (Check
Engine Lamp) refer to Group 25, On-Board
Dianostics.
SOLID STATE FAN RELAYPCM OUTPUT
The radi ator fan runs at a vari abl e speed depend-
i ng on cool ant temperature and A/C system pressure.
The radi ator fan ci rcui t contai ns a Sol i d State Fan
Rel ay (SSFR). Refer to the Group 8W for a ci rcui t
schemati c.
A 5 vol t si gnal i s suppl i ed to the SSFR. The PCM
provi des a pul sed ground for the SSFR. Dependi ng
upon the amount of pul se on ti me, the SSFR puts out
a proporti onal vol tage to the fan motor at the l ower
speed. For i nstance, i f the on ti me i s 30 percent, then
the vol tage to the fan motor wi l l be 3.6 vol ts.
When engi ne cool ant reaches approxi matel y 102C
(215F) the PCM grounds the SSFR rel ay. I f engi ne
cool ant reaches 207C (225F) the PCM grounds the
hi gh speed ground rel ay and hi gh speed fan rel ay. I f
the fan operates at hi gh speed, the PCM de-energi zes
the hi gh speed rel ay and hi gh speed ground rel ay
when cool ant temperature drops to approxi matel y
101C (214F). When cool ant temperature drops to
101C (214F) the fan operates at l ow speed. The
PCM de-energi zes the l ow speed rel ay when cool ant
temperature drops to approxi matel y 93C (199F).
Al so, when the ai r condi ti oni ng pressure swi tch
cl oses, the fan operates at hi gh speed. The ai r condi -
ti oni ng swi tch cl oses at 285 psi 10 psi . When ai r
condi ti oni ng pressure drops approxi matel y 40 psi , the
pressure swi tch opens and the fan operates at l ow
speed.
The SSFR rel ay i s l ocated on the l eft front i nner
frame just behi nd the radi ator (Fi g. 42).
SPEED CONTROL SOLENOIDSPCM OUTPUT
The speed control vacuum and vent sol enoi ds are
operated by the PCM. When the PCM suppl i es a
ground to the vacuum and vent sol enoi ds, the speed
control system opens the throttl e pl ate. When the
PCM removes the ground from the vacuum and vent
sol enoi ds, the throttl e bl ade cl oses. The PCM bal -
Fig. 41 Ignition Coil 3.3/3.8L
Fig. 42 Fan Control Module
ances the two sol enoi ds to mai ntai n the set speed.
Refer to Group 8H for speed control i nformati on.
TACHOMETERPCM OUTPUT
The PCM suppl i es engi ne RPM to the i nstrument
panel tachometer through the CCD Bus. The CCD
Bus i s a communi cati ons port. Vari ous modul es use
the CCD Bus to exchange i nformati on. Refer to
Group 8E for more i nformati on.
THROTTLE BODY
On al l engi ne assembl i es (2.4, 3.0, and 3.3/3.8L)
the throttl e bodys are l ocated on the l eft si de of the
i ntake mani fol d pl enum. The throttl e body houses
the throttl e posi ti on sensor and the i dl e ai r control
motor. Ai r fl ow through the throttl e body i s con-
trol l ed by a cabl e operated throttl e bl ade l ocated i n
the base of the throttl e body (Fi g. 43) or (Fi g. 44) or
(Fi g. 45).
VISUAL INSPECTION2. 4L ENGINE
routed wi res and hoses shoul d be made before
attempti ng to di agnose or servi ce the fuel i njecti on
system. A vi sual check hel ps save unnecessary test
and di agnosti c ti me. A thorough vi sual i nspecti on wi l l
i ncl ude the fol l owi ng checks:
(1) Check i gni ti on cabl e routi ng from the coi l pack
to the spark pl ugs. Veri fy the cabl e are routed i n the
correct order and are ful l y seated to the coi l and
spark pl ug.
(2) Check di rect i gni ti on system (DI S) coi l el ectri -
cal connecti on for damage and a compl ete connecti on
to the coi l pack (Fi g. 46).
Fig. 43 Throttle Body2.4L
Fig. 44 Throttle Body3.0L
(3) Veri fy the camshaft posi ti on sensor el ectri cal
connector i s connected to the harness and not dam-
aged (Fi g. 47).
(4) Ensure the engi ne temperature sensor el ectri -
cal connector i s connected to the sensor and not dam-
aged (Fi g. 48).
(5) Veri fy the qui ck connect fuel fi tti ng i s ful l y
i nserted on the fuel suppl y tube.
(6) Check the oi l pressure sendi ng uni t el ectri cal
connecti on.
(7) Veri fy the el ectri cal connector at the knock sen-
sor i s ful l y seated and not damaged (Fi g. 49).
Fig. 45 Throttle Body3.3/3.8L
Fig. 46 Ignition Coil Pack Electrical Connection
(8) Veri fy the el ectri cal connector i s attached to
the Proporti onal purge sol enoi d (Fi g. 50) and not
damaged.
(9) Veri fy the vacuum connecti on at the Propor-
ti onal purge sol enoi d i s secure and not l eaki ng.
(10) Veri fy the hoses are securel y attached to the
EVAP cani ster (Fi g. 51).
(11) Ensure the harness connectors for the fuel
i njectors are attached to the correct i njector and not
damaged.
(12) Veri fy the fuel i njector harness and engi ne
wi ri ng harness connectors are ful l y i nserted i nto the
mai n wi ri ng harness.
(13) Check the vacuum connecti ons at the throttl e
body and i ntake pl enum.
Fig. 51 Evaporative Canister
(14) Ensure the i dl e ai r control motor and TPS
el ectri cal connectors are ful l y seated and not dam-
aged (Fi g. 52).
(15) I nspect the park/neutral swi tch wi ri ng connec-
ti on for damage. Ensure the automati c transaxl e
el ectri cal connecti ons are not damaged (Fi g. 53).
(16) I nspect the PCV system connecti ons for dam-
age (Fi g. 54).
(17) I nspect the crankshaft posi ti on sensor el ectri -
cal connector for damage (Fi g. 55).
(18) Veri fy the Mani fol d Absol ute Pressure (MAP)
sensor el ectri cal connector i s attached to the sensor
and not damaged (Fi g. 56).
(19) Check the heated oxygen sensor el ectri cal con-
nectors for damage (Fi g. 57) and (Fi g. 58).
(20) Veri fy the engi ne ground strap i s attached at
the engi ne and dash panel . I nspect the strap for cor-
rosi on or damage.
(21) I nspect the generator wi ri ng connecti ons for
damage.
Fig. 52 Throttle Body Electrical Connections
Fig. 53 Automatic Transaxle Electrical Connections
Fig. 54 PCV Valve
(22) Check the accessory dri ve bel t tensi on.
(23) Check the 40-way el ectri cal connectors at the
Powertrai n Control Modul e (PCM) (Fi g. 59) for dam-
age or spread termi nal s. Veri fy that the connectors
are ful l y i nserted i nto the PCM sockets. Ensure the
wi res are not stretched or pul l ed out of the connector.
(24) I nspect fuses i n the Power Di stri buti on Cen-
ter (PDC). Veri fy al l fuses and rel ays are ful l y
i nserted i nto the PDC (Fi g. 60). A l abel affi xed to the
undersi de of the PDC cover i denti fi es the rel ays and
fuses i n the PDC.
(25) I nspect battery cabl e connecti ons for corro-
si on.
(26) Check the power brake booster hose connec-
ti on (wi thout anti -l ock brake systems) (Fi g. 61).
(27) I nspect the speed control vacuum connecti on.
(28) I nspect hose and wi ri ng connecti ons at fuel
pump modul e. Check that wi ri ng connector i s maki ng
contact wi th termi nal s on pump.
Fig. 56 Map Sensor
Fig. 57 Upstream Heated Oxygen Sensor
Connectors
VISUAL INSPECTION3. 0L ENGINE
(1) Check for correct spark pl ug cabl e routi ng.
Ensure that the cabl es are compl etel y connected to
the spark pl ugs and di stri butor.
(2) Check i gni ti on coi l el ectri cal connecti ons (Fi g.
62).
(3) Veri fy that the el ectri cal connector i s attached
to the Proporti onal Purge Sol enoi d (Fi g. 63).
(4) Veri fy that vacuum connecti on at the duty cycl e
Proporti onal Purge Sol enoi d val ve i s secure and not
l eaki ng.
Fig. 61 Power Brake Booster Hose
Fig. 62 Ignition Coil Electrical Connection
Fig. 63 Proportional Purge Solenoid Valve
(5) Veri fy that the el ectri cal connector i s attached
to the MAP sensor (Fi g. 64).
(6) Check generator wi ri ng connecti ons. Ensure
the accessory dri ve bel t has proper tensi on.
(7) Veri fy that hoses are securel y attached to the
evaporati ve cani ster (Fi g. 65).
the engi ne and dash panel (Fi g. 66).
(9) Ensure the heated oxygen sensor connector i s
connected to the harness connector.
(10) Veri fy the di stri butor connector i s connected
to the harness connector (Fi g. 67).
(11) Veri fy the cool ant temperature sensor connec-
tor i s connected to the harness connector (Fi g. 68).
(12) Check vacuum hose connecti on at fuel pres-
sure regul ator and i ntake pl enum connector (Fi g. 68).
Fig. 64 Map Sensor Electrical and Vacuum
Connections
Fig. 66 Engine Ground Strap
Fig. 67 Distributor Connector
Connections and Vacuum Hose Connections at the
Air Intake Plenum
(13) Ensure the harness connector i s securel y
attached to each fuel i njector.
connecti on (Fi g. 69).
(15) Check hose connecti ons at throttl e body.
(16) Check throttl e body el ectri cal connecti ons
(Fi g. 70).
(17) Check PCV hose connecti ons (Fi g. 71).
(18) Check EGR system vacuum hose connecti ons
(Fi g. 72).
(19) Check EGR tube to i ntake pl enum connec-
ti ons.
(20) Check power brake booster vacuum connec-
ti ons.
(21) Check engi ne harness to mai n harness el ectri -
cal connecti ons.
(22) Check al l el ectroni c automati c transaxl e el ec-
tri cal connecti ons (Fi g. 73).
(23) I nspect the Powertrai n Control Modul e (PCM)
40-way el ectri cal connectors for damage or spread
Fig. 69 Oil Pressure Sending Unit Electrical
Connection
Fig. 70 Throttle Body Electrical and Vacuum Hose
Connections
Fig. 71 Positive Crankcase Ventilation (PCV) System
Fig. 72 EGR System
Fig. 73 Electronic Automatic Transaxle Electrical
Connections
termi nal s. Veri fy the connectors are ful l y i nserted
i nto the socket of the PCM (Fi g. 74). Ensure that
fuses i n the PDC.
(25) Check Battery Cabl e Connecti ons.
(26) Check hose and wi ri ng connecti ons at fuel
VISUAL INSPECTION3. 3/3. 8L ENGINES
(1) Check i gni ti on cabl e routi ng from the coi l pack
to the spark pl ugs. Veri fy the cabl e are routed i n the
correct order and are ful l y seated to the coi l and
spark pl ug.
(2) Check di rect i gni ti on system (DI S) coi l el ectri -
cal connecti on for damage and a compl ete connecti on
to the coi l pack (Fi g. 75).
(3) Veri fy the camshaft posi ti on sensor el ectri cal
connector i s connected to the harness and not dam-
aged (Fi g. 76).
(4) Ensure the engi ne temperature sensor el ectri -
cal connector i s connected to the sensor and not dam-
aged (Fi g. 77).
(5) Veri fy the qui ck connect fuel fi tti ng i s ful l y
i nserted on the fuel suppl y tube.
connecti on (Fi g. 78).
Fig. 75 Ignition Coil Pack Electrical Connection
(7) Veri fy the el ectri cal connector at the knock sen-
sor i s ful l y seated and not damaged (Fi g. 78).
(8) Veri fy the el ectri cal connector i s attached to
the Proporti onal purge sol enoi d (Fi g. 79) and not
damaged.
(9) Veri fy the vacuum connecti on at the Propor-
ti onal purge sol enoi d i s secure and not l eaki ng (Fi g.
79).
(10) Veri fy the hoses are securel y attached to the
EVAP cani ster (Fi g. 80).
(11) Ensure the harness connectors for the fuel
i njectors are attached to the correct i njector and not
damaged.
(12) Veri fy the fuel i njector harness and engi ne
wi ri ng harness connectors are ful l y i nserted i nto the
mai n wi ri ng harness.
Fig. 78 Knock Sensor and Oil Pressure Sending
Unit Electrical Connection
(13) Check the vacuum connecti ons at the throttl e
body and i ntake pl enum (Fi g. 81).
(14) Ensure the i dl e ai r control motor and TPS
el ectri cal connectors are ful l y seated and not dam-
aged (Fi g. 82).
(15) I nspect the park/neutral swi tch wi ri ng connec-
ti on for damage. Ensure the automati c transaxl e
el ectri cal connecti ons are not damaged (Fi g. 83).
(16) I nspect the PCV system connecti ons for dam-
age (Fi g. 84).
(17) I nspect the crankshaft posi ti on sensor el ectri -
cal connector for damage (Fi g. 85).
(18) Veri fy the Mani fol d Absol ute Pressure (MAP)
sensor el ectri cal connector i s attached to the sensor
and not damaged (Fi g. 86).
Fig. 81 Throttle Body Vacuum Connections
Fig. 82 Throttle Body Electrical Connections
Fig. 83 Automatic Transaxle Electrical Connections
Fig. 84 PCV Valve and Fresh Air Hose
(19) Check the heated oxygen sensor el ectri cal con-
nectors for damage (Fi g. 87) and (Fi g. 88).
the engi ne and dash panel . I nspect the strap for cor-
rosi on or damage.
(21) I nspect the generator wi ri ng connecti ons for
damage.
(22) Check the accessory dri ve bel t tensi on.
(23) Check the 40-way el ectri cal connectors at the
Powertrai n Control Modul e (PCM) (Fi g. 89) for dam-
age or spread termi nal s. Veri fy that the connectors
are ful l y i nserted i nto the PCM sockets. Ensure the
Fig. 86 MAP Sensor
Connectors
fuses i n the PDC.
(25) I nspect battery cabl e connecti ons for corro-
si on.
(26) Check the power brake booster hose connec-
ti on (wi thout anti -l ock brake systems) (Fi g. 91).
(27) I nspect the speed control vacuum connecti on
(Fi g. 92).
(28) I nspect hose and wi ri ng connecti ons at fuel
ASD AND FUEL PUMP RELAYS
The following description of operation and
tests apply only to the Automatic Shutdown
(ASD) and fuel pump relays. The termi nal s on the
bottom of each rel ay are numbered (Fi g. 93) or (Fi g.
94).
OPERATION
Termi nal number 30 i s connected to battery vol t-
age. For both the ASD and fuel pump rel ays, termi -
nal 30 i s connected to battery vol tage at al l ti mes.
Fig. 91 Power Brake Booster Hose
Fig. 92 Speed Control Vacuum
Fig. 93 ASD and Fuel Pump Relay Terminals
The PCM grounds the coi l si de of the rel ay
through termi nal number 85.
Termi nal number 86 suppl i es vol tage to the coi l
si de of the rel ay.
When the PCM de-energi zes the ASD and fuel
pump rel ays, termi nal number 87A connects to termi -
nal 30. Thi s i s the Off posi ti on. I n the off posi ti on,
vol tage i s not suppl i ed to the rest of the ci rcui t. Ter-
mi nal 87A i s the center termi nal on the rel ay.
When the PCM energi zes the ASD and fuel
pump rel ays, termi nal 87 connects to termi nal 30.
Thi s i s the On posi ti on. Termi nal 87 suppl i es vol tage
to the rest of the ci rcui t.
TESTING
The fol l owi ng procedure appl i es to the ASD and
fuel pump rel ays.
(1) Remove rel ay from connector before testi ng.
(2) Wi th the rel ay removed from the vehi cl e, use
an ohmmeter to check the resi stance between termi -
nal s 85 and 86. The resi stance shoul d be between 75
5 ohms.
(3) Connect the ohmmeter between termi nal s 30
and 87A. The ohmmeter shoul d show conti nui ty
between termi nal s 30 and 87A.
and 30. The ohmmeter shoul d not show conti nui ty at
thi s ti me.
(5) Connect one end of a jumper wi re (16 gauge or
smal l er) to rel ay termi nal 85. Connect the other end
of the jumper wi re to the ground si de of a 12 vol t
power source.
(6) Connect one end of another jumper wi re (16
gauge or smal l er) to the power si de of the 12 vol t
power source. Do not attach the other end of the
jumper wire to the relay at this time.
WARNING: DO NOT ALLOW OHMMETER TO CON-
TACT TERMINALS 85 OR 86 DURING THIS TEST.
(7) Attach the other end of the jumper wi re to
rel ay termi nal 86. Thi s acti vates the rel ay. The ohm-
meter shoul d now show conti nui ty between rel ay ter-
mi nal s 87 and 30. The ohmmeter shoul d not show
conti nui ty between rel ay termi nal s 87A and 30.
(8) Di sconnect jumper wi res.
(9) Repl ace the rel ay i f i t di d not pass the conti nu-
i ty and resi stance tests. I f the rel ay passed the tests,
i t operates properl y. Check the remai nder of the ASD
and fuel pump rel ay ci rcui ts. Refer to group 8W, Wi r-
i ng Di agrams.
To perform a compl ete test of the MAP sensor and
test the MAP sensor onl y, refer to the fol l owi ng:
CAUTION: When testing the MAP sensor, be sure
that the harness wires are not damaged by the test
meter probes.
(1) Test the MAP sensor output vol tage at the
MAP sensor connector between termi nal s 2 and 3
(Fi g. 95). Wi th the i gni ti on swi tch ON and the engi ne
not runni ng, output vol tage shoul d be 4 to 5 vol ts.
The vol tage shoul d drop to 1.5 to 2.1 vol ts wi th a hot,
neutral i dl e speed condi ti on. I f OK, go to next step. I f
not OK, go to step 3.
(2) Test PCM termi nal 36 for the same vol tage
descri bed i n the previ ous step to veri fy wi re harness
condi ti on. Repai r as requi red.
(3) Test the MAP sensor ground ci rcui t at sensor
connector termi nal 1 and PCM termi nal 43. I f OK, go
to next step. I f not OK, repai r as requi red.
(4) Test MAP sensor suppl y vol tage between sen-
sor connector termi nal s 2 and 1 wi th the key ON.
The vol tage shoul d be approxi matel y 5 vol ts (.5V).
Fi ve vol ts (.5V) shoul d al so be at termi nal 61 of the
Fig. 95 MAP Sensor Connector
PCM. I f OK, repl ace MAP sensor. I f not OK, repai r or
repl ace the wi re harness as requi red.
HEATED OXYGEN SENSOR
Use an ohmmeter to test the heati ng el ement of
the oxygen sensors. Di sconnect the el ectri cal connec-
tor from each oxygen sensor. The whi te wi res i n the
sensor connector are the power and ground ci rcui ts
for the heater. Connect the ohmmeter test l eads to
termi nal s of the whi te wi res i n the heated oxygen
sensor connector. Repl ace the heated oxygen sensor i f
the resi stance i s not between 4 and 7 ohms.
KNOCK SENSOR
The engi ne knock sensor i s affected by a number of
factors. A few of these are: i gni ti on ti mi ng, cyl i nder
pressure, fuel octane, etc. The knock sensor gener-
ates an AC vol tage whose ampl i tude i ncreases wi th
the i ncrease of engi ne knock. The knock sensor can
be tested wi th a di gi tal vol tmeter. The RMS vol tage
starts at about 20mVac (at about 700 rpm) and
i ncreases to approxi matel y 600 mVac (5000 rpm). I f
the output fal l s outsi de of thi s range a DTC wi l l be
set.
CAMSHAFT AND CRANKSHAFT POSITION SENSOR
Refer to Group 8D, I gni ti on for Di agnosi s and Test-
i ng of Camshaft and Crankshaft Sensors.
(1) Wi th the key off, di sconnect wi re harness con-
nector from cool ant temperature sensor (Fi g. 96) or
(Fi g. 97) or (Fi g. 98).
(2) Connect a hi gh i nput i mpedance (di gi tal ) vol t-
ohmmeter to termi nal s A and B (Fi g. 99). The ohm-
meter shoul d read as fol l ows:
(a) ECT STET at normal operati ng temperature
around 200F shoul d read approxi matel y 700 to
1,000 ohms.
(b) ECT STET at room temperature around 70F
ohmmeter shoul d read approxi matel y 7,000 to
13,000 ohms.
(3) Test the resi stance of the wi re harness between
the PCM connector termi nal 26 and the sensor har-
ness connector. Al so check for conti nui ty between
PCM connector termi nal 43 and the sensor harness
connector. Refer to Group 8W, Wi ri ng di agrams for
3.8L
ci rcui t i nformati on. I f the resi stance i s greater than 1
ohm, repai r the wi re harness as necessary.
test the throttl e posi ti on sensor onl y, refer to the fol -
l owi ng:
mi nal i s ground.
THROTTLE BODY MINIMUM AIR FLOW CHECK
PROCEDURE
(1) Warm engi ne i n Park or Neutral unti l the cool -
i ng fan has cycl ed on and off at l east once.
(2) Ensure that al l accessori es are off.
(4) 3.0L Engine
(a) Hook-up the ti mi ng check devi ce and tachom-
eter.
(b) Di sconnect the engi ne cool ant temperature
sensor and set basi c ti mi ng to 12 BTDC 2.
(c) Shut off engi ne. Reconnect cool ant tempera-
ture sensor wi re.
(5) Di sconnect the PCV val ve hose from the i ntake
mani fol d ni ppl e (Fi g. 101), (Fi g. 102) or (Fi g. 103).
(6) Cap the PCV val ve ni ppl e.
(7) 3.3/3.8L Engines
(a) I nstal l Ai r Meteri ng Fi tti ng 6457 (0.125 i n.
ori fi ce) to the i ntake mani fol d PCV ni ppl e (Fi g.
100).
(b) Di sconnect the i dl e purge l i ne from the throt-
tl e body ni ppl e.
(a) I nstal l Ai r Meteri ng Fi tti ng 6457 (0.125 i n.
ori fi ce) to the purge ni ppl e on the throttl e body.
(a) Cap the 3/16 i nch ni ppl e.
(b) Connect the DRB scan tool to the data l i nk
connector.
(10) Restart the engi ne. Al l ow engi ne to i dl e unti l
the cool i ng fan has cycl ed on and off at l east one
180F cycl e.
(11) Usi ng the DRB scan tool , access the Mi ni mum
Ai rfl ow I dl e Speed screen.
(12) The fol l owi ng wi l l then occur:
I dl e ai r control motor wi l l ful l y cl ose.
I dl e spark advance wi l l become fi xed.
DRB scan tool di spl ays engi ne rpm.
(13) I f i dl e rpm i s wi thi n the range shown i n the
I dl e Speci fi cati on chart, throttl e body mi ni mum ai r-
fl ow i s set correctl y.
IDLE SPECIFICATIONS2.4L ENGINE
Odometer Reading Idle RPM
Bel ow 1000 Mi l es . . . . . . . . . . . . . . . . .500-875 RPM
Above 1000 Mi l es . . . . . . . . . . . . . . . . .550875 RPM
Fig. 100 Air Metering Fitting 6457
IDLE SPECIFICATIONS3.0L ENGINE
Bel ow 1000 Mi l es . . . . . . . . . . . . . . . . .560-910 RPM
Above 1000 Mi l es . . . . . . . . . . . . . . . . .610-910 RPM
IDLE SPECIFICATIONS3.3/3.3L ENGINE
Bel ow 1000 Mi l es . . . . . . . . . . . . . . . . .525875 RPM
Above 1000 Mi l es . . . . . . . . . . . . . . . . .575875 RPM
(14) I f i dl e rpm i s not wi thi n speci fi cati ons, shut
off the engi ne and cl ean the throttl e body as fol l ows:
(a) Remove the throttl e body from engi ne.
WARNING: CLEAN THROTTLE BODY IN A WELL
VENTILATED AREA. WEAR RUBBER OR BUTYL
GLOVES, DO NOT LET MOPAR PARTS CLEANER
COME IN CONTACT WITH EYES OR SKIN. AVOID
INGESTING THE CLEANER. WASH THOROUGHLY
AFTER USING CLEANER.
(b) Whi l e hol di ng the throttl e open, spray the
enti re throttl e body bore and the mani fol d si de of
the throttl e pl ate wi th Mopar Parts Cl eaner. Only
use Mopar Parts Cleaner to clean the throttle
body.
(c) Usi ng a soft scuff pad, cl ean the top and bot-
tom of throttl e body bore and the edges and mani -
fol d si de of the throttl e bl ade. The edges of the
throttle blade and portions of the throttle
bore that are closest to the throttle blade
when closed, must be free of deposits.
(d) Use compressed ai r to dry the throttl e body.
(e) I nspect throttl e body for forei gn materi al .
(f) I nstal l throttl e body on mani fol d.
(g) Repeat steps 1 through 12. I f the mi ni mum
ai r fl ow i s sti l l not wi thi n speci fi cati ons, the prob-
l em i s not caused by the throttl e body.
(16) Remove Ai r Meteri ng Fi tti ng 6457 from the
i ntake mani fol d PCV ni ppl e. Rei nstal l the PCV val ve
hose.
(17) Uncap the throttl e body i dl e purge ni ppl e and
connect the i dl e purge l i ne.
(18) Remove DRB scan tool .
Fig. 101 PCV Valve2.4L Engine
Fig. 103 PCV Valve3.3/3.8L Engines
THROTTLE BODY
REMOVAL
(1) Di sconnect negati ve cabl e from battery cabl e.
(2) Remove ai r i nl et to throttl e body hose cl amp.
(3) Remove 2 screws and ai r i nl et resonator (Fi g.
104).
(4) Remove throttl e and the speed control (i f
equi pped) cabl es from l ever and bracket (Fi g. 105).
(5) Di sconnect el ectri cal connectors from the i dl e
ai r control motor and throttl e posi ti on sensor (TPS)
(Fi g. 106) or (Fi g. 107) or (Fi g. 108).
(6) Di sconnect vacuum hoses from throttl e body.
(7) Remove throttl e body to i ntake mani fol d
attachi ng nuts.
(8) Remove throttl e body and gasket.
INSTALLATION
(1) Reverse procedure for i nstal l ati on. Ti ghten
throttl e body mounti ng nuts to 25 Nm (225 i n. l bs.)
torque.
FUEL PUMP RELAY
The fuel pump rel ay i s l ocated i n the PDC. The
i nsi de top of the PDC cover has a l abel showi ng rel ay
and fuse l ocati on.
AUTOMATIC SHUTDOWN (ASD) RELAY
The Automati c Shutdown rel ay (ASD) rel ay i s
l ocated i n the PCD. The i nsi de top of the PDC cover
has a l abel showi ng rel ay and fuse l ocati on.
Attachment
Fig. 106 Throttle Body Electrical and Vacuum
Connections2.4L
Connections3.0L
REMOVAL
(2) Remove el ectri cal connector from throttl e posi -
ti on sensor.
(3) Remove throttl e posi ti on sensor mounti ng
screws.
(4) Li ft throttl e posi ti on sensor off throttl e shaft
(Fi g. 109), (Fi g. 110) or (Fi g. 111).
INSTALLATION
(1) I nstal l throttl e posi ti on sensor on throttl e
shaft. I nstal l mounti ng screws. Ti ghten screw to 2
(2) Connect el ectri cal connector to throttl e posi ti on
sensor.
IDLE AIR CONTROL MOTOR
When servi ci ng throttl e body components, al ways
reassembl e components wi th new O-ri ngs and seal s
where appl i cabl e. Never use l ubri cants on O-ri ngs or
seal s, damage may resul t. I f assembl y of component
i s di ffi cul t, use water to ai d assembl y. Use care when
removi ng hoses to prevent damage to hose or hose
ni ppl e.
REMOVAL
(2) Remove el ectri cal connector from i dl e ai r con-
trol motor.
(3) Remove i dl e ai r control motor mounti ng screws
(Fi g. 112).
(4) Remove motor from throttl e body. Ensure the
O-ri ng i s removed wi th the motor.
Connections3.3/3.8L
Fig. 109 Servicing Throttle Position Sensor2.4L
Fig. 110 Servicing Throttle Position Sensor3.0L
Fig. 111 Servicing Throttle Position Sensor3.3/3.8L
INSTALLATION
(1) The new i dl e ai r control motor has a new
O-ri ng i nstal l ed on i t. I f pi ntl e measures more than 1
i nch (25 mm) i t must be retracted. Use the DRB I dl e
Ai r Control Motor Open/Cl ose Test to retract the
pi ntl e (battery must be connected.)
(2) Careful l y pl ace i dl e ai r control motor i nto
throttl e body.
(3) I nstal l mounti ng screws. Ti ghten screws to 2
(4) Connect el ectri cal connector to i dl e ai r control
motor.
SENSOR2. 4/3. 3/3. 8L
REMOVAL
sor (Fi g. 113).
(2) Remove two screws hol di ng sensor to the
i ntake mani fol d.
INSTALLATION
SENSOR3. 0L
REMOVAL
(1) Remove vacuum hose and mounti ng screws
from mani fol d absol ute pressure (MAP) sensor (Fi g.
114).
Remove sensor.
INSTALLATION
PROPORTIONAL PURGE SOLENOID VALVE
REMOVAL
(1) Remove vacuum hose and el ectri cal connector
from sol enoi d (Fi g. 115).
(2) Pul l sol enoi d up to remove i t from mounti ng
bracket.
INSTALLATION
Reverse above procedure for i nstal l ati on.
Fig. 112 Servicing Idle Air Control Motor Fig. 113 Map Absolute Pressure Sensor
REMOVAL
cabl e fi rst.
(2) Remove 2 screws hol di ng Power Di stri buti on
Center (PDC) to bracket (Fi g. 116).
(3) Remove heat shi el d from battery (Fi g. 117).
(6) Rotate PDC toward center of vehi cl e to remove
from rear bracket (Fi g. 119).
(7) Pul l PDC rearward to remove from front
bracket. Lay PDC asi de to al l ow access to Powertrai n
Control Modul e (PCM).
(8) Squeeze tabs on 40-way connector. Pul l connec-
tor rearward to remove from PCM (Fi g. 120). Remove
both way connectors.
Fig. 115 Proportional Purge Solenoid Valve
Fig. 116 Power Distribution Center Retaining Screws
(9) Remove 3 screws hol di ng PCM to fender (Fi g.
121).
(10) Remove PCM from vehi cl e.
INSTALLATION
(1) Connect 2 40-Way el ectri cal connectors to PCM
(Fi g. 120).
(2) I nstal l PCM. Ti ghten mounti ng screws.
(3) I nstal l PDC bracket.
For removal /i nstal l ati on procedures refer to group
8D - I gni ti on System, Servi ce Procedures.
For removal /i nstal l ati on procedures refer to group
8D - I gni ti on System, Servi ce Procedures.
UPSTREAM OXYGEN SENSOR
The oxygen sensor i s i nstal l ed i n the exhaust man-
i fol d (Fi g. 122) or (Fi g. 123) or (Fi g. 124).
CAUTION: Do not pull on the oxygen sensor wire
when unplugging the electrical connector.
WARNING: THE EXHAUST MANIFOLD AND CATA-
LYTIC CONVERTER MAY BE EXTREMELY HOT. USE
CARE WHEN SERVICING THE OXYGEN SENSOR.
REMOVAL
(2) Unpl ug oxygen sensor el ectri cal connector.
(3) Use a socket such as Snap-On YA8875 or
equi val ent to remove sensor.
Fig. 119 PDC Rear Bracket
Fig. 120 PCM 40-Way Connectors
Fig. 121 PCM Removal/Installation
Fig. 122 Upstream Heated Oxygen Sensor2.4L
(4) When the sensor i s removed, the exhaust man-
i fol d threads must be cl eaned wi th an 18 mm X 1.5 +
6E tap. I f usi ng ori gi nal sensor, coat the threads wi th
Locti te 771-64 anti -sei ze compound or equi val ent.
INSTALLATION
(1) Reverse removal procedure to i nstal l a new
sensor.
New sensors are packaged wi th compound on the
threads and no addi ti onal compound i s requi red. The
sensor must be ti ghtened to 27 Nm (20 ft. l bs.)
torque.
DOWNSTREAM OXYGEN SENSOR
REMOVAL
WARNING: THE EXHAUST MANIFOLD MAY BE
EXTREMELY HOT. USE CARE WHEN SERVICING
THE OXYGEN SENSOR.
(2) Remove grommet cover to expose connector
(Fi g. 125).
(3) Push l ocki ng tab back and unpl ug oxygen sen-
sor el ectri cal connector (Fi g. 126).
(4) Use a socket such as Snap-On YA8875 or
equi val ent to remove sensor (Fi g. 127).
Fig. 124 Upstream Heated Oxygen Sensor3.3/3.8L
Fig. 125 Oxygen Sensor Grommet Cover
Fig. 126 Oxygen Sensor Connector Locking Tab
Fig. 127 Oxygen Sensor Removal/Installation
(5) When the sensor i s removed, the exhaust man-
i fol d threads must be cl eaned wi th an 18 mm X 1.5 +
6E tap. I f usi ng ori gi nal sensor, coat the threads wi th
Locti te 771-64 anti -sei ze compound or equi val ent.
INSTALLATION
(1) Reverse removal procedure to i nstal l a new
sensor.
New sensors are packaged wi th compound on the
threads and no addi ti onal compound i s requi red. The
sensor must be ti ghtened to 27 Nm (20 ft. l bs.)
torque.
KNOCK SENSOR
For removal /i nstal l ati on procedures refer to Group
8D- I gni ti on System, Servi ce Procedures.
AIR CLEANER ELEMENT
REMOVAL
(1) Remove 2 screws and ai r i nl et resonator (Fi g.
128).
(2) Loosen 3 cl amps hol di ng ai r cl eaner housi ng
hal ves together.
(3) Remove l eft si de of ai r cl eaner housi ng (Fi g.
129).
(4) Remove el ement from ai r cl eaner housi ng (Fi g.
130).
INSTALLATION
(1) I nstal l a new el ement i n housi ng.
(2) Posi ti on l eft si de of housi ng.
(3) Snap cl amps i nto pl ace.
(4) I nstal l hoses and ai r i nl et resonator.
Fig. 129 Air Cleaner Housing (Left Side)
Fig. 130 Air Cleaner Element
REMOVAL
System.
INSTALLATION
System.
REMOVAL
System.
INSTALLATION
System.
ENGINE COOLANT TEMPERATURE SENSOR3. 3/
3. 8L
REMOVAL
System.
INSTALLATION
System.
i ntake mani fol d pl enum (Fi g. 133).
REMOVAL
(1) Remove el ectri cal connector from sensor.
(2) Remove sensor.
INSTALLATION
(1) I nstal l sensor. Ti ghten sensor to 28 Nm (20 ft.
l bs.) torque.
SPECIFICATIONS
TORQUE
DESCRIPTION TORQUE
Generator Brkt. to I ntake Mani fol d Bol ts3.3/3.8L.54
Nm (40 ft. l bs.)
Cool ant Sensor2.4L . . . . . . . . . .7 Nm (62 i n. l bs.)
Cool ant Sensor3.0L . . . . . . . . . .7 Nm (62 i n. l bs.)
Cool ant Sensor3.3/3.8L. . . . . . . .7 Nm (62 i n. l bs.)
Cl y. Head to I ntake Mani fol d
Strut Bol ts3.3/3.8L. . . . . . . . 54 Nm (40 ft. l bs.)
EGR Tube to I ntake Mani fol d
Screws . . . . . . . . . . . . . . . . . .22 Nm (200 i n. l bs.)
I dl e Ai r Control Motor . . . . . . . . . .2 Nm (18 i n. l bs.)
I gni ti on Coi l Fasteners . . . . . . .12 Nm (105 i n. l bs.)
I ntake Ai r Temperature Sensor . .28 Nm (20 ft. l bs.)
MAP Sensor2.4L . . . . . . . . . . . .4 Nm (35 i n. l bs.)
MAP Sensor3.0L . . . . . . . . . . . .4 Nm (35 i n. l bs.)
MAP Sensor3.3/3.8L . . . . . . . . . .4 Nm (35 i n. l bs.)
Upstream O2S . . . . . . . . . . . . . . .27 Nm (20 ft. l bs.)
Downstream O2S . . . . . . . . . . . . .27 Nm (20 ft. l bs.)
Throttl e Body Bol ts . . . . . . . . . .26 Nm (225 i n. l bs.)
SPECIAL TOOLS
FUEL
Extractor C4334
Pressure Gauge Assembly C4799B
Fuel Pressure Test Adapter 6539
Spanner Wrench 6856
Metering Orifice
Fuel Line Tool
Fuel Line Adapter
Fuel Line Adapter 1/4
O2S (Oxygen Sensor) Remover/InstallerC-4907
FUEL SYSTEM2.5L DIESEL ENGINE/2.0L GAS ENGINE
CONTENTS
page page
FUEL DELIVERY SYSTEM2. 0L ENGINE . . . . 28
FUEL DELIVERY SYSTEM2. 5L DIESEL
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FUEL INJECTION SYSTEM2. 0L ENGINE . . . 32
FUEL INJECTION SYSTEM2. 5L DIESEL
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
GENERAL INFORMATION
INDEX
page page
GENERAL INFORMATION
FUEL REQUIREMENTS2.0L ENGINE . . . . . . . 2
FUEL REQUIREMENTS2.5L DIESEL . . . . . . . . 2
GASOLINE/OXYGENATE BLENDS . . . . . . . . . . . 2
INTRODUCTION2.0L ENGINE . . . . . . . . . . . . . 2
INTRODUCTION2.5L DIESEL . . . . . . . . . . . . . 1
GENERAL INFORMATION
INTRODUCTION2. 5L DIESEL
Certai n components of the fuel system on the 2.5L
di esel engi ne are control l ed by the Bosch Engi ne con-
trol l er whi ch i s a Powertrai n Control Modul e (PCM).
Refer to Powertrai n Control Modul e i n the Fuel
I njecti on System2.5L Di esel Engi ne secti on of thi s
group for a l i st of i tems control l ed by the PCM. The
Body Control Modul e (BCM) i s mounted to a bracket
l ocated i nsi de the vehi cl e under the dashpanel to the
l eft of the steeri ng col umn (Fi g. 1). The PCM i s
mounted at the base of the center consol e i n front of
the Ai r Bag Modul e. (Fi g. 2).
The Fuel System consi sts of: the fuel tank, fuel
i njecti on pump (engi ne mounted), fuel fi l ter/water
separator, fuel tank modul e, el ectri cal fuel gauge
sendi ng uni t, gl ow pl ugs, gl ow pl ug rel ay, PCM, and
al l the el ectri cal components that control the fuel
system. I t al so consi sts of fuel tubes/l i nes/hoses and
fi tti ngs, vacuum hoses, and fuel i njector(s).
A Fuel Return System. A separate fuel return
system i s used. Thi s wi l l route excess fuel : from the
fuel i njectors; through i ndi vi dual i njector drai n
tubes; through the fuel i njecti on pump overfl ow
val ve; and back to the fuel tank through a separate
fuel l i ne.
The Fuel Tank Assembly consi sts of: the fuel
tank, two pressure rel i ef/rol l over val ves, fuel fi l l er
tube, fuel tank modul e contai ni ng a fuel gauge send-
i ng uni t, and a pressure-vacuum fi l l er cap.
Fig. 1 BCM Location
NS/GS FUEL SYSTEM2. 5L DIESEL ENGINE/2. 0L GAS ENGINE 14 - 1
INTRODUCTION2. 0L ENGINE
Refer to the i ntroducti on i n group 14 for the 2.4/
3.0/3.3/3.8l engi nes.
FUEL REQUIREMENTS2. 5L DIESEL
Refer to the Lubri cati on and Mai ntenance secti on
of thi s manual for i nformati on. Al so refer to the
Owner Manual .
FUEL REQUIREMENTS2. 0L ENGINE
Your vehi cl e was desi gned to meet al l emi ssi on reg-
ul ati ons and provi de excel l ent fuel economy when
usi ng hi gh qual i ty unl eaded gasol i ne.
Use hi gh qual i ty unl eaded gasol i ne wi th a mi ni -
mum research octane rati ng of 91.
The vehi cl e wi l l operate on fuel s rangi ng from
unl eaded fuel havi ng a mi ni mum research octane of
91 to super unl eaded fuel wi th a mi ni mum research
octane of 98.
GASOLINE/OXYGENATE BLENDS
Refer to Gasol i ne/Oxygenate bl ends for the 2.4/3.0/
3.3/3.8l engi nes i n group 14.
Fig. 2 PCM Location
14 - 2 FUEL SYSTEM2. 5L DIESEL ENGINE/2. 0L GAS ENGINE NS/GS
FUEL DELIVERY SYSTEM2.5L DIESEL ENGINE
INDEX
page page
FUEL DRAIN TUBES . . . . . . . . . . . . . . . . . . . . . 7
FUEL FILTER/WATER SEPARATOR . . . . . . . . . . 4
FUEL GAUGE SENDING UNIT . . . . . . . . . . . . . . 4
FUEL HEATER RELAY . . . . . . . . . . . . . . . . . . . . 8
FUEL HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . 8
FUEL INJECTION PUMP . . . . . . . . . . . . . . . . . . 5
FUEL INJECTORS . . . . . . . . . . . . . . . . . . . . . . . 6
FUEL SHUTDOWN SOLENOID . . . . . . . . . . . . . 5
FUEL SYSTEM PRESSURE WARNING . . . . . . . 3
FUEL TANK MODULE . . . . . . . . . . . . . . . . . . . . 4
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FUEL TUBES/LINES/HOSES AND CLAMPS
LOW-PRESSURE TYPE . . . . . . . . . . . . . . . . . 6
HIGH-PRESSURE FUEL LINES . . . . . . . . . . . . . 7
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . 3
QUICK-CONNECT FITTINGSLOW PRESSURE
TYPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
WASTEGATE (TURBOCHARGER) . . . . . . . . . . . 8
AIR IN FUEL SYSTEM . . . . . . . . . . . . . . . . . . . 11
FUEL HEATER RELAY TEST . . . . . . . . . . . . . . 12
FUEL INJECTION PUMP TEST . . . . . . . . . . . . . 12
FUEL INJECTOR SENSOR TEST . . . . . . . . . . . 12
FUEL INJECTOR TEST . . . . . . . . . . . . . . . . . . 12
FUEL SHUTDOWN SOLENOID TEST . . . . . . . . 13
FUEL SUPPLY RESTRICTIONS . . . . . . . . . . . . 13
GENERAL INFORMATION . . . . . . . . . . . . . . . . . 9
HIGH-PRESSURE FUEL LINE LEAK TEST . . . . 14
VISUAL INSPECTION . . . . . . . . . . . . . . . . . . . . . 9
WASTEGATE (TURBOCHARGER) . . . . . . . . . . 14
SERVICE PROCEDURES
AIR BLEED PROCEDURES . . . . . . . . . . . . . . . 14
FUEL INJECTION PUMP TIMING . . . . . . . . . . . 15
ACCELERATOR PEDAL . . . . . . . . . . . . . . . . . . 16
AIR CLEANER ELEMENT . . . . . . . . . . . . . . . . . 16
FUEL DRAIN TUBES . . . . . . . . . . . . . . . . . . . . 16
FUEL FILTER/WATER SEPARATOR . . . . . . . . . 16
FUEL HEATER RELAY . . . . . . . . . . . . . . . . . . . 17
FUEL HEATER . . . . . . . . . . . . . . . . . . . . . . . . . 17
FUEL INJECTION PUMP . . . . . . . . . . . . . . . . . 19
FUEL INJECTORS . . . . . . . . . . . . . . . . . . . . . . 22
FUEL LEVEL SENSOR . . . . . . . . . . . . . . . . . . . 18
FUEL RESERVOIR MODULE . . . . . . . . . . . . . . 25
FUEL SHUTDOWN SOLENOID . . . . . . . . . . . . 23
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
HIGH-PRESSURE LINES . . . . . . . . . . . . . . . . . 26
SPECIFICATIONS
FUEL INJECTOR FIRING SEQUENCE . . . . . . . 27
FUEL SYSTEM PRESSURE . . . . . . . . . . . . . . . 27
FUEL TANK CAPACITY . . . . . . . . . . . . . . . . . . 27
IDLE SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . 27
INTRODUCTION
Thi s Fuel Del i very secti on wi l l cover components
not control l ed by the PCM. For components con-
trol l ed by the PCM, refer to the Fuel I njecti on Sys-
tem2.5L Di esel Engi ne secti on of thi s group.
The fuel heater rel ay, fuel heater and fuel gauge
are not operated by the PCM. These components are
control l ed by the i gni ti on (key) swi tch. Al l other fuel
system el ectri cal components necessary to operate
the engi ne are control l ed or regul ated by the PCM.
FUEL SYSTEM PRESSURE WARNING
WARNING: HIGHPRESSURE FUEL LINES DELIVER
DIESEL FUEL UNDER EXTREME PRESSURE FROM
THE INJECTION PUMP TO THE FUEL INJECTORS.
THIS MAY BE AS HIGH AS 45,000 KPA (6526 PSI).
USE EXTREME CAUTION WHEN INSPECTING FOR
HIGHPRESSURE FUEL LEAKS. INSPECT FOR
HIGHPRESSURE FUEL LEAKS WITH A SHEET OF
CARDBOARD (Fig. 1). HIGH FUEL INJECTION
PRESSURE CAN CAUSE PERSONAL INJURY IF
CONTACT IS MADE WITH THE SKIN.
FUEL TANK
The fuel tank and tank mounti ng used wi th the
di esel powered engi ne i s the same as used wi th gas-
ol i ne powered model s, al though the fuel tank modul e
i s di fferent.
The fuel tank contai ns the fuel tank modul e and
two rol l over val ves. Two fuel l i nes are routed to the
fuel tank modul e. One l i ne i s used for fuel suppl y to
the fuel fi l ter/water separator. The other i s used to
return excess fuel back to the fuel tank.
The fuel tank modul e contai ns the fuel gauge el ec-
tri cal sendi ng uni t. An electrical fuel pump is not
used with the diesel engine.
FUEL TANK MODULE
An el ectri c fuel pump i s not attached to the fuel
tank modul e for di esel powered engi nes. Fuel i s sup-
pl i ed by the fuel i njecti on pump.
The fuel tank modul e i s i nstal l ed i n the top of the
fuel tank (Fi g. 2). The fuel tank modul e contai ns the
fol l owi ng components:
Fuel reservoi r
A separate i n-tank fuel fi l ter
El ectri c fuel gauge sendi ng uni t
Fuel suppl y l i ne connecti on
Fuel return l i ne connecti on
FUEL GAUGE SENDING UNIT
The fuel gauge sendi ng uni t i s attached to the si de
of the fuel pump modul e. The sendi ng uni t consi sts of
a fl oat, an arm, and a vari abl e resi stor (track). The
track i s used to send an el ectri cal si gnal used for fuel
gauge operati on.
As the fuel l evel i ncreases, the fl oat and arm move
up. Thi s decreases the sendi ng uni t resi stance, caus-
i ng the fuel gauge on the i nstrument panel to read
ful l . As the fuel l evel decreases, the fl oat and arm
move down. Thi s i ncreases the sendi ng uni t resi s-
tance, causi ng the fuel gauge on the i nstrument
panel to read empty.
FUEL FILTER/WATER SEPARATOR
The fuel fi l ter/water separator assembl y i s l ocated
i n the engi ne compartment near the strut tower (Fi g.
3).
The combi nati on fuel fi l ter/water separator pro-
tects the fuel i njecti on pump by hel pi ng to remove
water and contami nants from the fuel . Moi sture col -
l ects at the bottom of the fi l ter/separator i n a pl asti c
bowl .
The fuel fi l ter/water separator assembl y contai ns
the fuel fi l ter, fuel heater el ement, and fuel drai n
val ve.
For i nformati on on the fuel heater, refer to Fuel
Heater i n thi s group.
Refer to the mai ntenance schedul es i n Group 0 i n
thi s manual for the recommended fuel fi l ter repl ace-
ment i nterval s.
Fig. 1 Typical Fuel Pressure Test at Injector
Fig. 2 Fuel Tank
Fig. 3 Fuel Filter/Water Separator Location
For peri odi c drai ni ng of water from the bowl , refer
to Fuel Fi l ter/Water Separator Removal /I nstal l ati on
i n thi s group.
FUEL SHUTDOWN SOLENOID
The fuel shutdown solenoid is controlled and
operated by the PCM.
The fuel shutdown (shut-off) sol enoi d i s used to
el ectri cal l y shut off the di esel fuel suppl y to the hi gh-
pressure fuel i njecti on pump. The sol enoi d i s
mounted to the rear of the i njecti on pump (Fi g. 4).
The sol enoi d control s starti ng and stoppi ng of the
engi ne regardl ess of the posi ti on of the accel erator
pedal . When the i gni ti on (key) swi tch i s OFF, the
sol enoi d i s shut off and fuel fl ow i s not al l owed to the
fuel i njecti on pump. When the key i s pl aced i n the
ON or START posi ti ons, fuel suppl y i s al l owed at the
i njecti on pump.
FUEL INJECTION PUMP
The fuel i njecti on pump i s a mechani cal di stri bu-
tortype, Bosch VP36 seri es (Fi g. 5). A gear on the
end of the i njecti on pump shaft meshes wi th the
dri ve gear at the front of engi ne. The pump i s
mechani cal l y ti med, rel ati ve to the posi ti on of the
cam and crankshaft. The PCM can make adjust-
ments to the ti mi ng of the i njecti on pump.
The i njecti on pump contai ns the fuel shutdown
sol enoi d, fuel temperature sensor, control sl eeve sen-
sor, fuel quanti ty actuator and the fuel ti mi ng sol e-
noi d (Fi g. 5).
I n the el ectroni cal l y control l ed i njecti on pump, the
pump pl unger works the same as the pump pl unger
i n a mechani cal l y control l ed i njecti on pump, but the
amount of fuel and the ti me the fuel i s i njected i s
control l ed by the vehi cl es PCM, i nstead of by a
mechani cal governor assembl y. A sol enoi d control l ed
by the PCM i s used i n pl ace of the mechani cal gov-
ernor assembl y, and i t moves a control sl eeve i nsi de
the pump that regul ates the amount of fuel bei ng
i njected. There i s no mechani cal connecti on between
the accel erator pedal and the el ectroni cal l y control l ed
i njecti on pump. I nstead, a sensor connected to the
accel erator pedal sends a si gnal to the PCM that rep-
resents the actual posi ti on of the accel erator pedal .
The PCM uses thi s i nput, al ong wi th i nput from
other sensors to move the control sl eeve to del i ver
the appropri ate amount of fuel . Thi s system i s known
as Dri ve-By-Wi re
The actual ti me that the fuel i s del i vered i s very
i mportant to the di esel combusti on process. The PCM
moni tors outputs from the engi ne speed sensor (fl y-
wheel posi ti on i n degrees), and the fuel i njector sen-
sor (mechani cal movement wi thi n the #1 cyl i nder
fuel i njector). Outputs from the Accel erator Pedal
Posi ti on sensor, engi ne speed sensor (engi ne rpm)
and engi ne cool ant temperature sensor are al so used.
The PCM wi l l then compare i ts set val ues to these
outputs to el ectri cal l y adjust the amount of fuel ti m-
i ng (amount of advance) wi thi n the i njecti on pump.
Thi s i s referred to as Cl osed Loop operati on. The
PCM moni tors fuel ti mi ng by compari ng i ts set val ue
to when the i njector #1 opens. I f the val ue i s greater
than a preset val ue a faul t wi l l be set.
Fig. 4 Fuel Shutdown Solenoid and Overflow Valve
Location
Fig. 5 Fuel Injection Pump
Actual el ectri c fuel ti mi ng (amount of advance) i s
accompl i shed by the fuel ti mi ng sol enoi d mounted to
the bottom of the i njecti on pump (Fi g. 5). Fuel ti mi ng
wi l l be adjusted by the PCM, whi ch control s the fuel
ti mi ng sol enoi d.
An overfl ow val ve i s attached i nto the fuel return
l i ne at the rear of the fuel i njecti on pump (Fi g. 4).
Thi s val ve serves two purposes. One i s to ensure that
a certai n amount of resi dual pressure i s mai ntai ned
wi thi n the pump when the engi ne i s swi tched off.
Thi s wi l l prevent the fuel ti mi ng mechani sm wi thi n
the i njecti on pump from returni ng to i ts zero posi -
ti on. The other purpose i s to al l ow excess fuel to be
returned to the fuel tank through the fuel return
l i ne. The pressure val ues wi thi n thi s val ve are preset
and can not be adjusted.
The fuel i njecti on pump suppl i es hi ghpressure
fuel of approxi matel y 45,000 kPa (6526 psi ) to each
i njector i n preci se metered amounts at the correct
ti me.
For mechani cal i njecti on pump ti mi ng, refer to
Fuel I njecti on Pump Ti mi ng i n the Servi ce Proce-
dures secti on of thi s group.
FUEL INJECTORS
Fuel drai n tubes (Fi g. 6) are used to route excess
fuel back to the overfl ow val ve (Fi g. 4) at the rear of
the i njecti on pump. Thi s excess fuel i s then returned
to the fuel tank through the fuel return l i ne.
The i njectors are connected to the fuel i njecti on
pump by the hi gh pressure fuel l i nes. A separate
i njector i s used for each of the four cyl i nders. An
i njector contai ni ng a sensor (Fi g. 7) i s used on the
cyl i nder number one i njector. Thi s i njector i s cal l ed
i nstrumented i njector #1 or needl e movement sensor.
I t i s used to tel l the PCM when the #1 i njectors
i nternal spri ng-l oaded val ve seat has been forced
open by pressuri zed fuel bei ng del i vered to the cyl i n-
der, whi ch i s at the end of i ts compressi on stroke.
When the i nstrumented i njectors val ve seat i s force
open, i t sends a smal l vol tage spi ke pul se to the
PCM. Thi s tel l s the PCM that the engi ne i s at TDC
on the number one cyl i nder. I t i s not used wi th the
other three i njectors.
Fuel enters the i njector at the fuel i nl et (top of
i njector) and i s routed to the needl e val ve bore. When
fuel pressure ri ses to approxi matel y 15,00015,800
kPa (21752291 psi ), the needl e val ve spri ng tensi on
i s overcome. The needl e val ve ri ses and fuel fl ows
through the spray hol es i n the nozzl e ti p i nto the
combusti on chamber. The pressure requi red to l i ft
the needl e val ve i s the i njector openi ng pressure set-
ti ng. Thi s i s referred to as the pop-off pressure set-
ti ng.
Fuel pressure i n the i njector ci rcui t decreases after
i njecti on. The i njector needl e val ve i s i mmedi atel y
cl osed by the needl e val ve spri ng and fuel fl ow i nto
the combusti on chamber i s stopped. Exhaust gases
are prevented from enteri ng the i njector nozzl e by
the needl e val ve.
A copper washer (gasket) i s used at the base of
each i njector (Fi g. 7) to prevent combusti on gases
from escapi ng.
Fuel i njector fi ri ng sequence i s 1342.
FUEL TUBES/LINES/HOSES AND CLAMPSLOW-
PRESSURE TYPE
Al so refer to the proceedi ng secti on on Qui ckCon-
nect Fi tti ngs.
I nspect al l hose connecti ons such as cl amps, cou-
pl i ngs and fi tti ngs to make sure they are secure and
Fig. 6 Fuel Injectors and Drain Tubes
Fig. 7 Fuel Injector Sensor
l eaks are not present. The component shoul d be
repl aced i mmedi atel y i f there i s any evi dence of deg-
radati on that coul d resul t i n fai l ure.
Never attempt to repai r a pl asti c fuel l i ne/tube or a
qui ckconnect fi tti ng. Repl ace compl ete l i ne/tube as
necessary.
Avoi d contact of any fuel tubes/hoses wi th other
vehi cl e components that coul d cause abrasi ons or
scuffi ng. Be sure that the fuel l i nes/tubes are prop-
erl y routed to prevent pi nchi ng and to avoi d heat
sources.
The l i nes/tubes/hoses are of a speci al constructi on.
I f i t i s necessary to repl ace these l i nes/tubes/hoses,
use onl y ori gi nal equi pment type.
The hose cl amps used to secure the rubber hoses
are of a speci al rol l ed edge constructi on. Thi s con-
structi on i s used to prevent the edge of the cl amp
from cutti ng i nto the hose. Onl y these rol l ed edge
type cl amps may be used i n thi s system. Al l other
types of cl amps may cut i nto the hoses and cause
fuel l eaks.
Where a rubber hose i s joi ned to a metal tube
(staked), do not attempt to repai r. Repl ace enti re
l i ne/tube assembl y.
Use new ori gi nal equi pment type hose cl amps.
Ti ghten hose cl amps to 2 Nm (20 i n. l bs.) torque.
QUICK-CONNECT FITTINGSLOW PRESSURE
TYPE
Di fferent types of qui ck-connect fi tti ngs are used to
attach vari ous fuel system components. These are: a
si ngl e-tab type, a two-tab type or a pl asti c retai ner
ri ng type (Fi g. 8). Refer to Qui ck-Connect Fi tti ngs i n
the Removal /I nstal l ati on secti on for more i nforma-
ti on.
CAUTION: The interior components (o-rings, spac-
ers) of quick-connect fitting are not serviced sepa-
rately, but new pull tabs are available for some
types. Do not attempt to repair damaged fittings or
fuel lines/tubes. If repair is necessary, replace the
complete fuel tube assembly.
HIGH-PRESSURE FUEL LINES
CAUTION: The highpressure fuel lines must be
held securely in place in their holders. The lines
cannot contact each other or other components. Do
not attempt to weld highpressure fuel lines or to
repair lines that are damaged. Only use the recom-
mended lines when replacement of highpressure
fuel line is necessary.
Hi ghpressure fuel l i nes del i ver fuel under pres-
sure of up to approxi matel y 45,000 kPa (6526 PSI )
from the i njecti on pump to the fuel i njectors. The
l i nes expand and contract from the hi ghpressure
fuel pul ses generated duri ng the i njecti on process. Al l
hi ghpressure fuel l i nes are of the same l ength and
i nsi de di ameter. Correct hi ghpressure fuel l i ne
usage and i nstal l ati on i s cri ti cal to smooth engi ne
operati on.
WARNING: USE EXTREME CAUTION WHEN
INSPECTING FOR HIGHPRESSURE FUEL LEAKS.
INSPECT FOR HIGHPRESSURE FUEL LEAKS WITH
A SHEET OF CARDBOARD. HIGH FUEL INJECTION
FUEL DRAIN TUBES
These rubber tubes are l owpressure type.
Some excess fuel i s conti nual l y vented from the
fuel i njecti on pump. Duri ng i njecti on, a smal l amount
of fuel fl ows past the i njector nozzl e and i s not
i njected i nto the combusti on chamber. Thi s fuel
drai ns i nto the fuel drai n tubes (Fi g. 9) and back to
the tee banjo fi tti ng, whi ch i s connected to the same
l i ne as the overfl ow val ve, whi ch al l ows a vari abl e
quanti ty to return to the fuel tank. The overfl ow
val ve i s cal i brated to open at a preset pressure.
Excess fuel not requi red by the pump to mai ntai n the
mi ni mum pump cavi ty pressure i s then returned
through the overfl ow val ve and on to the fuel tank
through the fuel return l i ne.
Fig. 8 Plastic Retainer Ring-Type Fitting
FUEL HEATER
The fuel heater i s used to prevent di esel fuel from
waxi ng duri ng col d weather operati on. The fuel
heater i s l ocated i n the bottom pl asti c bowl of the
fuel fi l ter/water separator (Fi g. 10).
The el ement i nsi de the heater assembl y i s made of
a Posi ti ve Temperature Coeffi ci ent (PTC) materi al ,
and has power appl i ed to i t by the fuel heater rel ay
anyti me the i gni ti on key i s i n the on posi ti on. PTC
materi al has a hi gh resi stance to current fl ow when
i ts temperature i s hi gh, whi ch means that i t wi l l not
generate heat when the temperature i s above a cer-
tai n val ue. When the temperature i s bel ow 7C (45
F), the resi stance of the PTC el ement i s l owered, and
al l ows current to fl ow through the fuel heater el e-
ment warmi ng the fuel . When the temperature i s
above 29C (85 F), the PTC el ements resi stance
ri ses, and current fl ow through the heater el ement
stops.
Vol tage to operate the fuel heater i s suppl i ed from
the i gni ti on (key) swi tch and through the fuel heater
rel ay. Refer to the fol l owi ng Fuel Heater Rel ay for
addi ti onal i nformati on. The fuel heater and fuel
heater relay are not controlled by the Power-
train Control Module (PCM).
Current draw for the heater el ement i s 150 watts
at 14 vol ts (DC).
FUEL HEATER RELAY
Vol tage to operate the fuel heater i s suppl i ed from
the i gni ti on (key) swi tch through the fuel heater
rel ay. The PCM is not used to control this relay.
The fuel heater rel ay i s l ocated i n the PDC. The
PDC i s l ocated next to the battery i n the engi ne com-
partment (Fi g. 11). For the l ocati on of the rel ay
wi thi n the PDC, refer to l abel on PDC cover.
WASTEGATE (TURBOCHARGER)
Refer to Group 11, Exhaust System and I ntake
Mani fol d for i nformati on.
Fig. 9 Fuel Drain Tubes
Fig. 10 Fuel Heater Temperature Sensor and
Element Location
Fig. 11 Relay Location
GENERAL INFORMATION
Thi s secti on of the group wi l l cover a general di ag-
nosi s of di esel engi ne fuel system components.
Diagnostic Trouble Codes: Refer to On-Board
Di agnosti cs i n Group 25, Emi ssi on Control System
for a l i st of Di agnosti c Troubl e Codes (DTCs) for cer-
tai n fuel system components.
The PCM must be tested wi th the DRBI I I scan
tool . The DRBI I I shoul d be the fi rst step i n any di ag-
nosi s of engi ne performance compl ai nts. Refer to the
1997 GS 2.5L Di esel Powertrai n Di agnosti c Proce-
dures manual for di agnosi s and testi ng of the di esel
engi ne control system.
VISUAL INSPECTION
A vi sual i nspecti on for l oose, di sconnected, or i ncor-
rectl y routed wi res and hoses shoul d be made before
attempti ng to di agnose or servi ce the di esel fuel
i njecti on system. A vi sual check wi l l hel p fi nd these
condi ti ons. I t al so saves unnecessary test and di ag-
nosti c ti me. A thorough vi sual i nspecti on of the fuel
i njecti on system i ncl udes the fol l owi ng checks:
(1) Be sure that the battery connecti ons are ti ght
and not corroded.
(2) Be sure that the 68 way connector i s ful l y
engaged wi th the PCM (Fi g. 12).
(3) Veri fy that the el ectri cal connecti ons for the
Di esel PCM rel ay are cl ean and free of corrosi on.
Thi s rel ay i s l ocated i n the PDC. For the l ocati on of
the rel ay wi thi n the PDC, refer to l abel on PDC
cover.
(4) Veri fy that the el ectri cal connecti ons for the
fuel heater rel ay are cl ean and free of corrosi on. Thi s
rel ay i s l ocated i n the PDC. For the l ocati on of the
rel ay wi thi n the PDC, refer to l abel on PDC cover.
(5) Be sure the el ectri cal connectors at the ends of
the gl ow pl ugs (Fi g. 13) are ti ght and free of corro-
si on.
(6) Be sure that the el ectri cal connecti ons at the
gl ow pl ug rel ay are ti ght and not corroded. The gl ow
pl ug rel ay i s l ocated i n the engi ne compartment on
the l efti nner fender (Fi g. 14).
Fig. 12 PCM LocationTypical
Fig. 13 Glow Plug Connector
Fig. 14 Glow Plug Relay Location
(7) I nspect the starter motor and starter sol enoi d
connecti ons for ti ghtness and corrosi on.
(8) Veri fy that the el ectri cal connector i s fi rml y
connected to the fuel shutdown sol enoi d. I nspect the
connector for corrosi on or damaged wi res. The sol e-
noi d i s mounted to the rear of the i njecti on pump
(Fi g. 15).
(9) Veri fy that the fuel heater el ectri cal connector
i s fi rml y attached to the fi l ter bowl at the bottom of
the fuel fi l ter/water separator. I nspect the connector
for corrosi on or damaged wi res.
(10) Veri fy that the el ectri cal pi gtai l connector
(sensor connector) (Fi g. 16) for the fuel i njector sen-
sor i s fi rml y connected to the engi ne wi ri ng harness.
I nspect the connector for corrosi on or damaged wi res.
Thi s sensor i s used on the #1 cyl i nder i njector onl y.
(11) Veri fy that the el ectri cal pi gtai l connector
(sensor connector) (Fi g. 17) for the fuel ti mi ng sol e-
noi d i s fi rml y connected to the engi ne wi ri ng har-
ness. I nspect the connector for corrosi on or damaged
wi res. The fuel ti mi ng sol enoi d i s l ocated on the bot-
tom of the fuel i njecti on pump (Fi g. 17).
(12) I nspect for exhaust system restri cti ons such
as pi nched exhaust pi pes or a col l apsed or pl ugged
muffl er.
(13) Veri fy that the harness connector i s fi rml y
connected to the vehi cl e speed sensor (Fi g. 18).
(14) Veri fy turbocharger wastegate operati on.
Refer to Group 11, Exhaust System and I ntake Man-
i fol d Group for i nformati on.
(15) Veri fy that the harness connector i s fi rml y
connected to the engi ne cool ant temperature sensor.
The sensor i s l ocated on the si de of cyl i nder head
near the rear of fuel i njecti on pump (Fi g. 19).
(16) Check for ai r i n the fuel system. Refer to the
Ai r Bl eed Procedure.
(17) I nspect al l fuel suppl y and return l i nes for
si gns of l eakage.
(18) Be sure that the ground connecti ons are ti ght
and free of corrosi on. Refer to Group 8, Wi ri ng for
l ocati ons of ground connecti ons.
(19) I nspect the ai r cl eaner el ement (fi l ter) for
restri cti ons.
(20) Be sure that the turbocharger output hose i s
properl y connected to the charge ai r cool er (i nter-
cool er) i nl et tube. Veri fy that the charge ai r cool er
output hose i s properl y connected to the cool er and
Fig. 15 Fuel Shutdown Solenoid Location
Fig. 17 Fuel Timing Solenoid
the i ntake mani fol d. Refer to Group 11, Exhaust Sys-
tem and I ntake Mani fol d for i nformati on.
(21) Be sure that the vacuum hoses to the vacuum
pump are connected and not l eaki ng. The pump i s
l ocated on the front of engi ne (i nternal ) and i s dri ven
from the crankshaft gear and chai n (Fi g. 20). Di scon-
nect the hose and check for mi ni mum vacuum from
the pump. Refer to Group 5, Brake System for spec-
i fi cati ons and procedures.
(22) Be sure that the accessory dri ve bel t i s not
damaged or sl i ppi ng.
(23) Veri fy there i s a good connecti on at the engi ne
speed sensor. Refer to the Fuel I njecti on System i n
thi s secti on for l ocati on of the engi ne speed sensor
l ocati on.
(24) Veri fy there i s a good connecti on at the Mass
Ai r Fl ow Sensor, whi ch i s a part of the ai r i ntake
assembl y.
AIR IN FUEL SYSTEM
Ai r wi l l enter the fuel system whenever the fuel
suppl y l i nes, fuel fi l ter/water separator, fuel fi l ter
bowl , i njecti on pump, hi ghpressure l i nes or i njectors
are removed or di sconnected. Ai r wi l l al so enter the
fuel system whenever the fuel tank has been run
empty.
Ai r trapped i n the fuel system can resul t i n hard
starti ng, a rough runni ng engi ne, engi ne mi sfi re, l ow
power, excessi ve smoke and fuel knock. After servi ce
i s performed, ai r must be bl ed from the system
before starti ng the engi ne.
I nspect the fuel system from the fuel tank to the
i njectors for l oose connecti ons. Leaki ng fuel i s an
i ndi cator of l oose connecti ons or defecti ve seal s. Ai r
can al so enter the fuel system between the fuel tank
and the i njecti on pump. I nspect the fuel tank and
fuel l i nes for damage that mi ght al l ow ai r i nto the
system.
For ai r bl eedi ng, refer to Ai r Bl eed Procedure i n
the Servi ce Procedures secti on of thi s group.
Fig. 18 Vehicle Speed SensorTypical
Location
Fig. 20 Vacuum Pump at Front of Engine
FUEL HEATER RELAY TEST
The fuel heater rel ay i s l ocated i n the Power Di s-
tri buti on Center (PDC). Refer to Rel aysOperati on/
Testi ng i n Fuel I ngecti on System secti on of thi s
group for test procedures.
FUEL INJECTOR TEST
The fuel i njecti on nozzel s, l ocated on the engi ne
cyl i nder head, spray fuel under hi gh pressure i nto
the i ndi vi dual combusti on chambers. Pressuri zed
fuel , del i vered by the fuel i njecti on pump, unseats a
spri ng-l oaded needl e val ve i nsi de the i njector, and
the fuel i s atomi zed as i t escapes through the i njector
openi ng i nto the engi nes combusti on chamber. I f the
fuel i njector does not operate properl y, the engi ne
may mi sfi re, or cause other dri veabi l i ty probl ems.
A l eak i n the i njecti on pumptoi njector hi ghpres-
sure fuel l i ne can cause many of the same symptoms
as a mal functi oni ng i njector. I nspect for a l eak i n the
hi ghpressure l i nes before checki ng for a mal func-
ti oni ng fuel i njector.
WARNING: THE INJECTION PUMP SUPPLIES HIGH-
PRESSURE FUEL OF UP TO APPROXIMATELY
45,000 KPA (6526 PSI) TO EACH INDIVIDUAL INJEC-
TOR THROUGH THE HIGHPRESSURE LINES. FUEL
UNDER THIS AMOUNT OF PRESSURE CAN PENE-
TRATE THE SKIN AND CAUSE PERSONAL INJURY.
WEAR SAFETY GOGGLES AND ADEQUATE PRO-
TECTIVE CLOTHING. AVOID CONTACT WITH FUEL
SPRAY WHEN BLEEDING HIGHPRESSURE FUEL
LINES.
WARNING: DO NOT BLEED AIR FROM THE FUEL
SYSTEM OF A HOT ENGINE. DO NOT ALLOW FUEL
TO SPRAY ONTO THE EXHAUST MANIFOLD WHEN
BLEEDING AIR FROM THE FUEL SYSTEM.
To determi ne whi ch fuel i njector i s mal functi oni ng,
run the engi ne and l oosen the hi ghpressure fuel l i ne
nut at the i njector (Fi g. 21). Li sten for a change i n
engi ne speed. I f engi ne speed drops, the i njector was
operati ng normal l y. I f engi ne speed remai ns the
same, the i njector may be mal functi oni ng. After test-
i ng, ti ghten the l i ne nut to 30 Nm (22 ft. l bs.)
torque. Test al l i njectors i n the same manner one at
a ti me.
Once an i njector has been found to be mal functi on-
i ng, remove i t from the engi ne and test i t. Refer to
the Removal /I nstal l ati on secti on of thi s group for pro-
cedures.
After the i njector has been removed, i nstal l i t to a
benchmount i njector tester. Refer to operati ng
i nstructi ons suppl i ed wi th tester for procedures.
The openi ng pressure or pop pressure shoul d be
15,00015,800 kPa (21752291 psi ). I f the fuel i njec-
tor needl e val ve i s openi ng (poppi ng) to earl y or to
l ate, repl ace the i njector.
FUEL INJECTOR SENSOR TEST
The fuel i njector sensor i s used onl y on the fuel
i njector for the number1 cyl i nder (Fi g. 22). I t i s not
used on the i njectors for cyl i nders number 2, 3, or 4.
To test the sensor, unpl ug the sensor connector
(Fi g. 22) from the engi ne wi ri ng harness. Check
resi stance across termi nal s. Resi stance shoul d be 110
ohms 10 ohms at 20C (68F). Repl ace sensor i f
speci fi cati on cannot be met.
FUEL INJECTION PUMP TEST
The injection pump is not to be serviced or
the warranty may be voided. If the injection
pump requires service, the complete assembly
must be replaced.
I ncorrect i njecti on pump ti mi ng (mechani cal or
el ectri cal ) can cause poor performance, excessi ve
smoke and emi ssi ons and poor fuel economy.
Fig. 21 Typical Inspection of Fuel Injector
Fig. 22 Fuel Injector Sensor Location
A defecti ve fuel i njecti on pump, defecti ve fuel ti m-
i ng sol enoi d or mi sadjusted mechani cal pump ti mi ng
can cause starti ng probl ems or prevent the engi ne
from revvi ng up. I t can al so cause:
Engi ne surge at i dl e
Rough i dl e (warm engi ne)
Low power
Excessi ve fuel consumpti on
Poor performance
Low power
Bl ack smoke from the exhaust
Bl ue or whi te fog l i ke exhaust
I ncorrect i dl e or maxi mum speed
The el ectroni cal l y control l ed fuel pump has no
mechani cal governor l i ke ol der mechani cal l y con-
trol l ed fuel pumps. Do not remove the top cover of
the fuel pump, or the screws fasteni ng the wi ri ng
pi gtai l to the si de of the pump. The warranty of
the injection pump and the engine may be void
if those seals have been removed or tampered
with.
FUEL SUPPLY RESTRICTIONS
LOWPRESSURE LINES
Restri cted or Pl ugged suppl y l i nes or fuel fi l ter can
cause a ti mi ng faul t that wi l l cause the PCM to oper-
ate the engi ne i n a Li mp Home mode. See the
i ntroducti on of the Fuel I njecti on System i n thi s
group for more i nformati on on the Li mp Home mode.
Fuel suppl y l i ne restri cti ons can cause starti ng prob-
l ems and prevent the engi ne from revvi ng up. The
starti ng probl ems i ncl ude; l ow power and bl ue or
whi te fog l i ke exhaust. Test al l fuel suppl y l i nes for
restri cti ons or bl ockage. Fl ush or repl ace as neces-
sary. Bl eed the fuel system of ai r once a fuel suppl y
l i ne has been repl aced. Refer to the Ai r Bl eed Proce-
dure secti on of thi s group for procedures.
HIGHPRESSURE LINES
Restri cted (ki nked or bent) hi ghpressure l i nes can
cause starti ng probl ems, poor engi ne performance
and bl ack smoke from exhaust.
Exami ne al l hi ghpressure l i nes for any damage.
Each radi us on each hi ghpressure l i ne must be
smooth and free of any bends or ki nks.
Repl ace damaged, restri cted or l eaki ng hi ghpres-
sure fuel l i nes wi th the correct repl acement l i ne.
clamped securely in place in the holders. The lines
FUEL SHUTDOWN SOLENOID TEST
Si nce di esel fuel i njecti on does not use spark pl ugs
to start combusti on, the onl y way to stop the engi ne
i s to cut off the fuel suppl y. Thi s i s done wi th the
Fuel Shutdown Sol enoi d. I f the engi ne cranks, but
refuses to start, i t may be caused by a defecti ve fuel
shutdown sol enoi d.
The fuel shutdown solenoid is not controlled
or operated by the PCM. Vol tage to operate the
sol enoi d i s suppl i ed from the i gni ti on (key) swi tch.
NOTE: Although the fuel shutdown solenoid is not
operated by the PCM, if the Fuel Shutdown Solenoid
has been disconnected, and the key turned on, the
PCM will sense that the solenoid is not in the circuit,
and will switch to a Limp Home mode. After recon-
necting the solenoid, the PCM will have to be reset
by clearing the codes with the DRBIII scan tool, or
disconnecting the vehicles battery for several min-
utes. The DRBIII scan tool is the preferred method
for resetting the PCM. Refer to the 1998 GS 2.5L Die-
sel Powertrain Diagnostic Manual for procedure.
The fuel shutdown (shutoff) sol enoi d i s used to
el ectri cal l y shut off the di esel fuel suppl y to the hi gh-
pressure fuel i njecti on pump. The sol enoi d i s
mounted to the rear of the i njecti on pump (Fi g. 23).
The sol enoi d control s starti ng and stoppi ng of the
engi ne regardl ess of the posi ti on of the accel erator
pedal . When the i gni ti on (key) swi tch i s OFF, the sol e-
noi d i s shut off and fuel fl ow i s not al l owed to the fuel
i njecti on pump. When the key i s pl aced i n the ON or
START posi ti ons, fuel suppl y i s al l owed at the i njec-
ti on pump.
(1) Di sconnect the el ectri cal pi gtai l connector (test
connector) (Fi g. 23) from the mai n engi ne wi ri ng har-
ness. Do not di sconnect wi ri ng di rectl y at sol enoi d.
(2) Connect the l eads of a vol tmeter between a
good ground and the di sconnected engi ne wi ri ng har-
ness.
(3) Turn the key to the ON posi ti on. Do not
attempt to start engi ne.
(4) 12V+ shoul d be observed at wi ri ng harness. I f
not, refer to Group 8, Wi ri ng for wi ri ng schemati cs
and repai r as necessary.
(5) Turn the key to the START posi ti on. 12V+ shoul d
be observed at wi ri ng harness. I f not, refer to Group 8,
Wi ri ng for wi ri ng schemati cs and repai r as necessary.
The faul t may be i n the i gni ti on (key) swi tch.
12V+ must be observed i n both the ON and START
posi ti ons. I f 12V+ was observed, proceed to the next
step.
(6) Wi th key sti l l i n the ON posi ti on, connect and
di sconnect the wi ri ng harness to the sol enoi d. As thi s
i s done, a cl i cki ng noi se shoul d be heard comi ng from
the sol enoi d. I f not, repl ace sol enoi d. Refer to Fuel
Shutdown Sol enoi d i n the Removal /I nstal l ati on sec-
ti on of thi s group for procedures.
HIGH-PRESSURE FUEL LINE LEAK TEST
Hi ghpressure fuel l i ne l eaks can cause starti ng
probl ems and poor engi ne performance.
WARNING: DUE TO EXTREME FUEL PRESSURES
OF UP TO 45,000 KPA (6526 PSI), USE EXTREME
CAUTION WHEN INSPECTING FOR HIGHPRESSURE
FUEL LEAKS. DO NOT GET YOUR HAND, OR ANY
PART OF YOUR BODY NEAR A SUSPECTED LEAK.
INSPECT FOR HIGHPRESSURE FUEL LEAKS WITH
A SHEET OF CARDBOARD. HIGH FUEL INJECTION
Start the engi ne. Move the cardboard over the
hi ghpressure fuel l i nes and check for fuel spray onto
the cardboard (Fi g. 24). I f a hi ghpressure l i ne con-
necti on i s l eaki ng, bl eed the system and ti ghten the
connecti on. Refer to the Ai r Bl eed Procedure i n thi s
group for procedures. Repl ace damaged, restri cted or
l eaki ng hi ghpressure fuel l i nes wi th the correct
repl acement l i ne.
WASTEGATE (TURBOCHARGER)
Refer to Group 11, Exhaust System and I ntake
Mani fol d for i nformati on.
SERVICE PROCEDURES
AIR BLEED PROCEDURES
AIR BLEEDING AT FUEL FILTER
A certai n amount of ai r may become trapped i n the
fuel system when fuel system components are ser-
vi ced or repl aced. Bl eed the system as needed after
fuel system servi ce accordi ng to the fol l owi ng proce-
dures.
Some ai r enters the fuel system when the fuel fi l -
ter or i njecti on pump suppl y l i ne i s changed. Thi s
smal l amount of ai r i s vented automati cal l y from the
i njecti on pump through the fuel drai n mani fol d tubes
i f the fi l ter was changed accordi ng to i nstructi ons.
Ensure the bowl of the fuel fi l ter/water separator i s
ful l of fuel
I t may be necessary to manual l y bl eed the system
i f:
The bowl of the fuel fi l ter/water separator i s not
parti al l y fi l l ed before i nstal l ati on of a new fi l ter
The i njecti on pump i s repl aced
Fig. 24 Typical Test for Leaks with Cardboard
Hi ghpressure fuel l i ne connecti ons are l oosened
or l i nes repl aced
I ni ti al engi ne startup or startup after an
extended peri od of no engi ne operati on
Runni ng fuel tank empty
FUEL INJ ECTION PUMP BLEEDING
(1) I f the fuel i njecti on pump has been repl aced,
ai r shoul d be bl ed at the overfl ow val ve before
attempti ng to start engi ne.
(a) Loosen the overfl ow val ve (Fi g. 25) at the
rear of the i njecti on pump.
(b) Pl ace a towel bel ow the val ve.
WARNING: WHEN CRANKING THE ENGINE TO
BLEED AIR FROM THE INJECTION PUMP, THE
ENGINE MAY START. PLACE THE TRANSMISSION
IN NEUTRAL OR PARK AND SET PARKING BRAKE
BEFORE ENGAGING THE STARTER MOTOR.
CAUTION: Do not engage the starter motor for
more than 30 seconds at a time. Allow 2 minutes
between cranking intervals.
(2) Crank the engi ne for 30 seconds at a ti me to
al l ow ai r trapped i n the i njecti on pump to vent out
the fuel i njector drai n tubes. Conti nue thi s procedure
unti l the engi ne starts. Observe the previ ous WARN-
I NG and CAUTI ON.
(3) Ti ghten overfl ow val ve.
HIGHPRESSURE FUEL LINE BLEEDING
WARNING: THE INJECTION PUMP SUPPLIES HIGH-
PRESSURE FUEL OF APPROXIMATELY 59,000 KPA
(8,557 PSI) TO EACH INDIVIDUAL INJECTOR
THROUGH THE HIGHPRESSURE LINES. FUEL
UNDER THIS AMOUNT OF PRESSURE CAN PENE-
TRATE THE SKIN AND CAUSE PERSONAL INJURY.
WEAR SAFETY GOGGLES AND ADEQUATE PRO-
TECTIVE CLOTHING AND AVOID CONTACT WITH
FUEL SPRAY WHEN BLEEDING HIGHPRESSURE
FUEL LINES.
Bl eed ai r from one i njector at ti me.
(1) Loosen the hi ghpressure fuel l i ne fi tti ng at
the i njector (Fi g. 26).
(2) Crank the engi ne unti l al l ai r has been bl ed
from the l i ne. Do not operate the starter motor
for longer than 30 seconds. Wait 2 minutes
between cranking intervals.
(3) Start the engi ne and bl eed one i njector at a
ti me unti l the engi ne runs smoothl y.
FUEL INJECTION PUMP TIMING
Refer to Removal /I nstal l ati on and Adjusti ng Fuel
Pump Ti mi ng i n thi s Group.
Fig. 25 Overflow Valve
Fig. 26 Bleeding HighPressure Fuel LineTypical
ACCELERATOR PEDAL
CAUTION: Be careful not to damage or kink the
cable core wire (within the cable sheathing) while
servicing the accelerator pedal or throttle cable.
REMOVAL
(1) Di sconnect el ectri cal connector.
(2) Remove accel erator pedal mounti ng bracket
nuts. Remove accel erator pedal assembl y.
INSTALLATION
(1) Pl ace accel erator pedal assembl y over studs
protrudi ng from fl oor pan. Ti ghten mounti ng nuts to
(2) Connect el ectri cal connector.
(3) Before starti ng the engi ne, operate the accel er-
ator pedal to check for any bi ndi ng.
AIR CLEANER ELEMENT
REMOVAL
(1) Remove hose cl amp at Mass Ai r Fl ow Sensor.
(2) Remove hose from Mass Ai r Fl ow Sensor.
(3) Loosen 2 cl amps hol di ng ai r cl eaner housi ng
hal ves together.
(4) Remove l eft si de of ai r cl eaner housi ng.
(5) Remove el ement from ai r cl eaner housi ng.
INSTALLATION
(1) I nstal l a new el ement i n housi ng.
(2) Posi ti on l eft si de of housi ng.
(3) Snap cl amps i nto pl ace.
(4) I nstal l hoses and cl amps.
FUEL DRAIN TUBES
The fuel drai n tubes (Fi g. 28) are l owpressure
type.
Pul l each tube from the i njector for removal . Push
on for i nstal l ati on. Cl amps are not requi red for these
tubes.
FUEL FILTER/WATER SEPARATOR
The fuel fi l ter/water separator i s l ocated i n the
engi ne compartment on the ri ght si de near the shock
tower. (Fi g. 29).
The fuel fi l ter/water separator assembl y contai ns
the fuel fi l ter, fuel heater el ement, and fuel drai n
val ve (Fi g. 29).
DRAINING WATER FROM FILTER BOWL
Moi sture (water) col l ects at the bottom of the fi l ter/
separator i n a pl asti c bowl . Water enteri ng the fuel
i njecti on pump can cause seri ous damage to the
pump. Note that the bulb will be illuminated for
approximately 2 seconds each time the key is
initially placed in the ON position. This is done
for a bulb check.
Fig. 27 Accelerator Pedal Mounting-Typical
Fig. 28 Fuel Drain Tubes
WARNING: DO NOT ATTEMPT TO DRAIN WATER
FROM THE FILTER/SEPARATOR WITH THE ENGINE
HOT.
(1) The bottom of the fi l ter/separator bowl i s
equi pped wi th a drai n val ve (Fi g. 29). The drai n
val ve i s equi pped wi th a fi tti ng. Attach a pi ece of
rubber hose to thi s fi tti ng. Thi s hose i s to be used as
a drai n hose.
(2) Pl ace a drai n pan under the drai n hose.
(3) Wi th the engi ne not runni ng, open the drai n
val ve (unscrewdrai n val ve has ri ght hand threads)
from the fi l ter/separator bowl . To gai n access to thi s
fi tti ng, the two fi l tertomounti ng bracket nuts (Fi g.
29) may have to be l oosened a few turns.
(4) Hol d the drai n open unti l cl ean fuel exi ts the
drai n.
(5) After drai ni ng, cl ose drai n val ve.
(6) Remove rubber drai n hose.
(7) Di spose of mi xture i n drai n pan accordi ng to
appl i cabl e l ocal or federal regul ati ons.
FUEL FILTER REMOVAL
(1) Drai n al l fuel and/or water from fuel fi l ter/wa-
ter separator assembl y. Refer to the previ ous Drai n-
i ng Water From Fi l ter Bowl .
(2) Unpl ug the el ectri cal connectors at bottom of
pl asti c bowl .
(3) Remove pl asti c bowl from bottom of fuel fi l ter
(unscrews).
(4) Remove fuel fi l ter from bottom of fi l ter base
(unscrews).
FUEL FILTER INSTALLATION
(1) Cl ean bottom of fuel fi l ter base.
(2) Appl y cl ean di esel fuel to new fuel fi l ter gasket.
(3) I nstal l and ti ghten fi l ter to fi l ter base. The bev-
el ed part of the rubber gasket shoul d be faci ng up
towards the fi l ter base.
(4) Cl ean the i nsi de of bowl wi th a soap and water
mi xture before i nstal l ati on. Careful l y cl ean any resi -
due between the two metal probes at the top of the
wateri nfuel sensor. Do not use chemi cal cl eaners
as damage to the pl asti c bowl may resul t.
(5) Pour di esel fuel i nto the pl asti c bowl before
i nstal l i ng bowl to bottom of fuel fi l ter. Do thi s to hel p
prevent ai r from enteri ng fuel i njecti on pump whi l e
attempti ng to starti ng engi ne.
(6) I nstal l fi l ter bowl to bottom of fi l ter.
(7) I nstal l the el ectri cal connectors at bottom of
bowl .
(8) Ti ghten the fi l tertomounti ng bracket nuts
(Fi g. 29) to 28 Nm (250 i n. l bs.) torque.
FUEL HEATER
I f the fuel heater el ement needs repl acement, the
pl asti c fi l ter bowl assembl y must be repl aced. Refer
to Fuel Fi l ter/Water Separator for i nformati on.
FUEL HEATER RELAY
The fuel heater rel ay i s l ocated i n the PDC. For
the l ocati on of the rel ay wi thi n the PDC (Fi g. 30),
refer to l abel on PDC cover.
Fig. 29 Fuel Filter/Water Separator Location
Fig. 30 Power Distribution Center (PDC) Location
FUEL LEVEL SENSOR
REMOVAL
Remove fuel reservoi r modul e. Refer to Fuel Reser-
voi r Modul e i n thi s secti on.
(1) Depress retai ni ng tab and remove the l evel
sensor connector from the BOTTOM of the fuel mod-
ul e el ectri cal connector (Fi g. 31).
NOTE: The pump module harness on TOP of flange
is not serviceable or removable.
(2) Pul l off bl ue l ocki ng wedge (Fi g. 32).
(3) Usi ng a smal l screwdri ver l i ft l ocki ng fi nger
away from termi nal and push termi nal out of connec-
tor (Fi g. 33).
(4) Push l evel sensor si gnal and ground termi nal s
out of the connector (Fi g. 34).
(5) I nsert a screwdri ver between the fuel modul e
and the top of the l evel sensor housi ng (Fi g. 35).
Push l evel sensor down sl i ghtl y.
(6) Sl i de l evel sensor wi res through openi ng fuel
modul e (Fi g. 36).
(7) Sl i de l evel sensor out of i nstal l ati on channel i n
modul e.
Fig. 31 Fuel Module/Level Sensor Electrical
Connector
Fig. 32 Wire Terminal Locking Wedge
Fig. 33 Wire Terminal Locking Finger
Fig. 34 Removing Wires From Connector
Fig. 35 Loosening Level Sensor
INSTALLATION
(1) I nsert l evel sensor wi res i nto bottom of openi ng
i n modul e.
(2) Wrap wi res i nto groove i n back of l evel sensor
(Fi g. 37).
(3) Whi l e feedi ng wi res i nto gui de grooves, sl i de
l evel sensor up i nto channel unti l i t snaps i nto pl ace
(Fi g. 38). Ensure tab at bottom of sensor l ocks i n
pl ace.
(4) I nstal l l evel sensor wi res i n connector. Push
the wi res up through the connector and then pul l
them down unti l they l ock i n pl ace. Ensure si gnal
and ground wi res are i nstal l ed i n the correct posi -
ti on.
(5) I nstal l l ocki ng wedge on connector.
(6) Push connector up i nto bottom of fuel modul e
el ectri cal connector.
(7) I nstal l fuel modul e. Refer to Fuel Reservoi r
FUEL INJECTION PUMP
REMOVAL
(1) Di sconnect negati ve battery cabl e at battery.
(2) Thoroughl y cl ean the area around the i njecti on
pump and fuel l i nes of al l di rt, grease and other con-
tami nants. Due to the close internal tolerances
of the injection pump, this step must be per-
formed before removing pump.
(3) Remove the engi ne accessory dri ve bel t. Refer
to Group 7, Cool i ng System for procedures.
(4) Remove the generator assembl y.
(5) Remove the rubber fuel return and suppl y
hoses from metal l i nes at pump (Fi g. 39).
(6) Remove the el ectri cal connector at engi ne cool -
ant temperature sensor (Fi g. 40).
(7) Di sconnect the Fuel I njecti on Pump el ectri cal
connector at fuel pump. (Fi g. 39).
Fig. 36 Level Sensor Removal/Installation
Fig. 37 Groove in Back Side of Level Sensor
Fig. 38 Installation Channel
Fig. 39 Overflow Valve and Fuel Shutdown Solenoid
(8) Di sconnect the mai n engi ne wi ri ng harness
from the gl ow pl ugs.
(9) Di sconnect the four hi ghpressure fuel l i nes
from the fuel i njecti on pump. Al so di sconnect fuel
l i nes at the fuel i njectors. For procedures, refer to
Hi ghPressure Fuel Li nes i n thi s group. Pl ace a rag
beneath the fi tti ngs to catch excess fuel .
(10) Remove pl ug from ti mi ng gear cover.
(11) The Top Dead Center (TDC) compressi on fi r-
i ng stroke must be determi ned as fol l ows:
(a) Remove the val ve cover, refer to Group 9,
Val ve Cover Removal /I nstal l ati on.
(b) Remove the ri ght front ti re and spl ash
shi el d. Usi ng a socket attached to the end of crank-
shaft, rotate the engi ne (countercl ockwi se as
vi ewed from front).
(c) Rotate the engi ne unti l cyl i nder #4 rockers
are i n between movement.
(d) Remove rocker arm assembl y.
(e) Remove val ve spri ng and keepers. CAU-
TION: When the piston is at TDC there is only
2 mm (.080 thousand) clearance between the
valve and piston.
(f) Let the val ve set on top of pi ston. I nstal l a
di al i ndi cator to the top of the val ve stem.
(g) Rotate engi ne back and forth to fi nd the TDC
posi ti on wi th the i ndi cator on the val ve stem. Mark
the damper and ti mi ng cover for TDC.
NOTE: On later model 1997 engines, a hole in the
bottom of the clutch housing can be lined up with a
hole in the flywheel, allowing the engine to be held
at TDC with a special alignment tool, part # VM1035.
(12) Remove i njecti on pump dri ve gear nut (Fi g.
41) and washer. CAUTION: Be very careful not to
drop the washer into the timing gear cover.
(13) A speci al 3pi ece gear removal tool set
VM.1003 (Fi g. 42) must be used to remove the i njec-
ti on pump dri ve gear from the pump shaft.
(a) Thread the adapter (Fi g. 43) i nto the ti mi ng
cover.
(b) Thread the gear pul l er i nto the i njecti on
pump dri ve gear (Fi g. 43). Thi s tool i s al so used to
hol d the gear i n synchroni zati on duri ng pump
removal .
(c) Remove the three i njecti on pumptogear
cover mounti ng nuts (Fi g. 44). CAUTION: This
step must be done to prevent breakage of the
Fig. 41 Removing Pump Drive Gear Nut
Fig. 42 Pump Gear Tools
three injection pump mounting flanges while
gear is being removed.
(d) I nstal l the dri ve bol t i nto the gear pul l er
(Fi g. 43). Ti ghten the dri ve bol t to press (remove)
the dri ve gear from i njecti on pump shaft whi l e
dri vi ng i njecti on pump rearward from ti mi ng gear
cover mounti ng studs.
(14) Remove pump from engi ne. Do not rotate
engine while gear puller is installed. Engine
damage will occur.
INSTALLATION/ADJ USTING PUMP TIMING
(1) Cl ean the mati ng surfaces of i njecti on pump
and ti mi ng gear cover.
(2) I nstal l a new i njecti on pumptoti mi ng gear
cover gasket.
(3) Remove the gear removi ng bol t (dri ve bol t)
from gear pul l er. CAUTION: Do not remove the
special gear puller or timing cover adapter
tools from timing cover at this time. Gear mis-
alignment will result.
(4) Pl ace the key way on the pump shaft to the 11
ocl ock posi ti on as vi ewed from the front of pump.
I nstal l the pump i nto the rear of ti mi ng gear cover
whi l e al i gni ng key way on pump shaft i nto pump gear.
(5) I nstal l and snug the 3 i njecti on pump mount-
i ng nuts. Thi s i s not the fi nal ti ghteni ng sequence.
(6) Remove the speci al gear pul l er and adapter
tool s from ti mi ng gear cover.
(7) I nstal l the i njecti on pump dri ve gear nut and
washer. Ti ghten nut to 88 Nm (65 ft. l bs.) torque.
(8) Remove access pl ug and pl ug washer at rear of
pump (Fi g. 45). Thread speci al di al i ndi cator adapter
tool VM.1011 (Fi g. 46) i nto thi s openi ng. Hand
ti ghten onl y.
(9) Attach speci al di al i ndi cator tool VM.1013 i nto
the adapter tool (Fi g. 46).
(10) Usi ng a socket attached to the end of crank-
shaft, rotate the engi ne (countercl ockwi se as
vi ewed from front) unti l thedi al i ndi cator stops mov-
i ng. Thi s rotati on i s about 20 to 30.
(11) Set the di al i ndi cator to 0 mm. Be sure the ti p of
di al i ndi cator i s touchi ng the ti p i nsi de the adapter tool .
(12) Very sl owl y rotate the crankshaft cl ockwi se
unti l movement on di al i ndi cator needl e has stopped.
Do not rotate crankshaft after needle move-
ment has stopped. Engine should be at TDC at
this point
(13) Check the TDC di al i ndi cator for TDC.
Fig. 43 Installing Pump Drive Gear Removal Tools
Fig. 44 Injection Pump Mounting Nuts
Fig. 45 Access Plug at Rear of Pump
(14) Gauge readi ng shoul d be at 0.60 mm. I f not,
the pump must be rotated for adjustment:
(a) Loosen the three i njecti on pump mounti ng
nuts at the mounti ng fl anges. These fl anges are
equi pped wi th sl otted hol es. The sl otted hol es are
used to rotate and posi ti on the i njecti on pump for
fuel ti mi ng. Loosen the three nuts just enough to
rotate the pump.
(b) Rotate the pump clockwise (as vi ewed from
front) unti l .60 mm i s i ndi cated on the di al i ndi ca-
tor gauge.
(c) Ti ghten the three pump mounti ng nuts to 30
(d) Recheck the di al i ndi cator after ti ghteni ng
the pump mounti ng nuts. Gauge shoul d sti l l be
readi ng 0.60 mm. Loosen pump mounti ng nuts and
readjust i f necessary.
(15) Remove di al i ndi cator and adapter tool s.
(16) I nstal l access pl ug and washer to rear of
i njecti on pump.
(17) I nstal l pl ug at ti mi ng gear cover.
(18) Remove di al i ndi cator from val ve stem.
(19) I nstal l val ve spri ng and keepers.
(20) I nstal l rocker arm assembl y and ti ghten nuts.
(21) I nstal l and connect the four hi ghpressure
fuel l i nes to the fuel i njecti on pump. Al so connect
fuel l i nes at the fuel i njectors. For procedures, refer
to Hi ghPressure Fuel Li nes i n thi s group.
(22) I nstal l el ectri cal connector at engi ne cool ant
temperature sensor.
(23) Connect el ectri cal connector at fuel shutdown
sol enoi d.
(24) Connect the mai n engi ne wi ri ng harness to
the gl ow pl ugs.
(25) Connect the fuel ti mi ng sol enoi d pi gtai l har-
ness to the engi ne wi ri ng harness.
(26) Connect the overfl ow val ve/banjo fi tti ng (fuel
return l i ne assembl y). Repl ace copper gaskets before
i nstal l i ng.
(27) Connect the rubber fuel return and suppl y
hoses to metal l i nes at pump. Ti ghten hose cl amps to
(28) I nstal l generator assembl y.
(29) I nstal l engi ne accessory dri ve bel t. Refer to
Group 7, Cool i ng System for procedures.
(30) I nstal l negati ve battery cabl e to battery.
(31) Start the engi ne and bri ng to normal operat-
i ng temperature.
(32) Check for fuel l eaks.
FUEL INJECTORS
Four fuel i njectors are used on each engi ne. Of these
four, two di fferent types are used. The fuel i njector used
on cyl i nder number one i s equi pped wi th a fuel i njector
sensor (Fi g. 47). The other three fuel i njectors are i den-
ti cal . Do not place the fuel injector equipped with
the fuel injector sensor into any other location
except the cylinder number one position.
REMOVAL
(1) Di sconnect negati ve battery cabl e at battery.
(2) Thoroughl y cl ean the area around the i njector
wi th compressed ai r.
(3) Remove the fuel drai n hoses (tubes) at each
i njector (Fi g. 48) bei ng servi ced. Each of these hoses
i s sl i pfi t to the fi tti ng on i njector.
(4) Remove the hi ghpressure fuel l i ne at i njector
bei ng removed. Refer to Hi ghPressure Fuel Li nes i n
thi s group for procedures.
(5) Remove the i njector usi ng speci al socket tool
number VM.1012A. When removi ng cyl i nder number
Fig. 46 Installing Dial Indicator and Special Adapter
Tools
Fig. 47 Fuel Injector SensorNumber1 Cylinder
one i njector, thread the wi ri ng harness through the
access hol e on the speci al socket (Fi g. 49).
(6) Remove and di scard the copper washer (seal ) at
bottom of i njector (Fi g. 47).
INSTALLATION
(1) Cl ean the i njector threads i n cyl i nder head.
(2) I nstal l new copper washer (seal ) to i njector.
(3) I nstal l i njector to engi ne. Ti ghten to 70 Nm
(52 ft. l bs.) torque.
(4) I nstal l hi ghpressure fuel l i nes. Refer to Hi gh-
Pressure Fuel Li nes i n thi s group for procedures.
(5) I nstal l fuel drai n hoses (tubes) to each i njector.
Do not use cl amps at fuel drai n hoses.
(6) Connect negati ve battery cabl e to battery.
(7) Bl eed the ai r from the hi ghpressure l i nes.
Refer to the Ai r Bl eed Procedure secti on of thi s
group.
FUEL SHUTDOWN SOLENOID
The sol enoi d i s mounted to the rear of the i njecti on
pump (Fi g. 50).
REMOVAL
(1) Thoroughl y cl ean the area around the sol enoi d
wi th compressed ai r.
(2) Di sconnect the fuel return l i ne and banjo fi t-
ti ng above the sol enoi d by removi ng (unthreadi ng)
the overfl ow val ve (Fi g. 50). Pl ace a towel bel ow the
val ve before removal . Di scard ol d seal i ng washers
after removal .
(3) Di sconnect the el ectri cal connector nut (Fi g.
50).
(4) Remove wi ri ng at sol enoi d.
(5) Remove sol enoi d from i njecti on pump.
INSTALLATION
(1) I nstal l sol enoi d i nto i njecti on pump.
(2) I nstal l wi ri ng and nut at sol enoi d.
(3) I nstal l new seal i ng washers to banjo fi tti ng.
(4) I nstal l overfl ow val ve, banjo fi tti ng and fuel
return l i ne to pump.
(5) Bl eed ai r from system. Refer to Ai r Bl eed Pro-
cedures i n thi s secti on of the group.
FUEL TANK
REMOVAL
properl y l abel ed diesel safety contai ner.
Fig. 48 Fuel InjectorTypical
Fig. 49 Wiring Harness Through Socket
(5) Di sconnect both the fuel fi l l and fuel vent rub-
ber hoses at the fuel tank.
(6) Di sconnect fuel suppl y and return l i nes from
the steel suppl y l i ne (Fi g. 51).
The fuel reservoir module electrical connec-
tor has a retainer that locks it in place.
(7) Sl i de el ectri cal connector l ock to unl ock (Fi g.
52).
(9) Use a transmi ssi on jack to support fuel tank.
Remove bol ts from fuel tank straps.
(10) Lower tank sl i ghtl y. Careful l y remove fi l l er
hose from tank.
(11) Lower the fuel tank. Remove cl amp and
remove fuel fi l l er tube vent hose. Remove fuel tank
from vehi cl e.
INSTALLATION
(1) Posi ti on fuel tank on transmi ssi on jack. Con-
nect fuel fi l l er tube vent hose and repl ace cl amp.
(2) Rai se tank i nto posi ti on and careful l y work
fi l l er tube i nto tank. A l i ght coati ng of cl ean engi ne
oi l on the tube end may be used to ai d assembl y.
(3) Feed fi l l er vent l i ne thru frame rai l . Careful
not to cross l i nes.
(4) Ti ghten strap bol ts to 54 Nm (40 ft. l bs.)
torque. Remove transmi ssi on jack.
CAUTION: Ensure straps are not twisted or bent
before or after tightening strap nuts.
(5) Connect modul e el ectri cal connector. Pl ace
retai ner i n l ocked posi ti on.
(6) Lubri cate the fuel suppl y and return l i nes wi th
cl ean 30 wei ght engi ne oi l , i nstal l the qui ck connect
Fuel Tank
Fig. 51 Fuel Tank and Lines
Lock
Fig. 53 Module Connector Retainer and Lock
fuel fi tti ng. Refer to Tube/Fi tti ng Assembl y i n the
Fuel Del i very secti on of thi s Group.
(7) Attach fi l l er l i ne to fi l l er tube. Pul l on connec-
tor to make sure of connecti on.
(8) Fi l l fuel tank, repl ace cap, and connect battery
negati ve cabl e.
FUEL RESERVOIR MODULE
REMOVAL
WARNING: THE FUEL RESERVOIR OF THE FUEL
MODULE DOES NOT EMPTY OUT WHEN THE TANK
IS DRAINED. THE FUEL IN THE RESERVOIR WILL
SPILL OUT WHEN THE MODULE IS REMOVED.
properl y l abel ed diesel safety contai ner.
(5) Use a transmi ssi on jack to support the fuel
tank. Remove bol ts from fuel tank straps. Lower
tank sl i ghtl y.
(6) Cl ean area around fuel reservoi r modul e and
tank to keep di rt and forei gn materi al out of tank.
(7) Di sconnect fuel l i nes from fuel modul e by
depressi ng qui ck connect retai ners wi th thumb and
fore fi nger (Fi g. 54).
(8) Sl i de modul e el ectri cal connector l ock to
unl ock.
(10) Usi ng Speci al Tool 6856, remove pl asti c l ock-
nut countercl ockwi se to rel ease pump modul e (Fi g.
56).
(11) Careful l y remove modul e and O-ri ng from
tank (Fi g. 57).
(12) Di scard ol d O-ri ng.
INSTALLATION
(1) Wi pe seal area of tank cl ean and pl ace a new
O-ri ng seal i n posi ti on on pump.
(2) Posi ti on fuel reservoi r modul e i n tank wi th
l ocknut.
(4) Connect fuel l i nes.
(5) Pl ug i n el ectri cal connector. Sl i de connector
l ock i nto posi ti on.
(6) Rai se fuel tank, i nstal l bol ts i nto fuel tank
straps and ti ghten.
(7) Lower vehi cl e on hoi st.
(8) Connect negati ve cabl e from battery.
(9) Fi l l fuel tank. Check for l eaks.
(10) I nstal l fuel fi l l er cap.
Lock
Fig. 55 Module Connector Retainer and Lock
Fig. 56 Fuel Reservoir Module Lock Nut Removal
HIGH-PRESSURE LINES
Al l hi ghpressure fuel l i nes are of the same l ength
and i nsi de di ameter. Correct hi ghpressure fuel l i ne
usage and i nstal l ati on i s cri ti cal to smooth engi ne
operati on.
REMOVAL
(1) Di sconnect negati ve battery cabl e from battery.
(2) Remove the necessary cl amps (Fi g. 58) hol di ng
the l i nes to the engi ne.
(3) Cl ean the area around each fuel l i ne connec-
ti on. Di sconnect each l i ne at the top of each fuel
i njector (Fi g. 59).
(4) Di sconnect each hi ghpressure l i ne fi tti ng at
each fuel i njecti on pump del i very val ve.
(5) Very careful l y remove each l i ne from the
engi ne. Note the posi ti on (fi ri ng order) of each l i ne
whi l e removi ng. Do not bend the line while
removing.
CAUTION: Be sure that the highpressure fuel lines
are installed in the same order that they were
removed. Prevent the injection pump delivery valve
holders (Fig. 58) from turning when removing or
installing highpressure lines from injection pump.
INSTALLATION
(1) Careful l y posi ti on each hi ghpressure fuel l i ne
to the fuel i njector and fuel i njecti on pump del i very
val ve hol der i n the correct fi ri ng order. Al so posi ti on
each l i ne i n the correct l i ne hol der.
(2) Loosel y i nstal l the l i ne cl amp/hol der bol ts.
(3) Ti ghten each l i ne at the del i very val ve to 30
(4) Ti ghten each l i ne at the fuel i njector to 30 Nm
Fig. 57 Fuel Reservoir Module Removal
Fig. 58 Fuel Lines and Clamps/Holders
Fig. 59 Fuel Lines at Fuel Injectors
Be sure the lines are not contacting each
other or any other component.
(5) Ti ghten the cl amp bracket bol ts to 24 Nm (18
ft. l bs.) torque.
(6) Bl eed ai r from the fuel system. Refer to the Ai r
Bl eed Procedure secti on of thi s group.
SPECIFICATIONS
FUEL TANK CAPACITY
75 Liters (20.0 Gals.)
Nomi nal refi l l capaci ti es are shown. A vari ati on
may be observed from vehi cl e to vehi cl e due to man-
ufacturi ng tol erances, ambi ent temperatures and
refi l l procedures.
IDLE SPEED
900 rpm 25 rpm wi th engi ne at normal operat-
i ng temperature.
FUEL INJECTOR FIRING SEQUENCE
1342
FUEL SYSTEM PRESSURE
Peak Injection Pressure/Fuel Injection Pump
Operating Pressure: 40,00045,000 kPa (5801
6526 psi ).
Opening Pressure of Fuel Injector:
15,00015,800 kPa (21752291 psi ).
FUEL DELIVERY SYSTEM2.0L ENGINE
INDEX
page page
ELECTRIC FUEL PUMP . . . . . . . . . . . . . . . . . . 28
FUEL DELIVERY SYSTEM . . . . . . . . . . . . . . . . 28
FUEL INJECTORS . . . . . . . . . . . . . . . . . . . . . . 28
FUEL LEVEL SENSOR . . . . . . . . . . . . . . . . . . . 28
FUEL PRESSURE REGULATOR . . . . . . . . . . . 28
FUEL PUMP MODULE . . . . . . . . . . . . . . . . . . . 28
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.0L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . 28
QUICK-CONNNECT FITTINGS
2.0L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . 28
FUEL INJECTORS2.0L ENGINE . . . . . . . . . . 29
FUEL LEVEL SENSOR2.0L ENGINE . . . . . . . 28
FUEL PUMP PRESSURE TEST
2.0L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . 28
SERVICE PROCEDURES
PROCEDURE2.0L ENGINE . . . . . . . . . . . . 29
HOSES AND CLAMPS2.0L ENGINE . . . . . . . 29
QUICK-CONNNECT FITTINGS2.0L ENGINE . 29
ACCELERATOR PEDAL . . . . . . . . . . . . . . . . . . 31
FUEL FILTER2.0L ENGINE . . . . . . . . . . . . . . 29
FUEL INJECTORS . . . . . . . . . . . . . . . . . . . . . . 30
FUEL LEVEL SENSOR2.0L ENGINE . . . . . . . 30
2.0L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.0L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . 29
FUEL PUMP MODULE2.0L ENGINE . . . . . . . 29
FUEL TANK2.0L ENGINE . . . . . . . . . . . . . . . 30
TORQUE SPECIFICATION . . . . . . . . . . . . . . . . 31
Refer to the Fuel Del i very Sytem i n the Fuel Del i v-
ery Secti on of group 14 for the 2.4/3.0/3.3/3.8L
engi nes for more i nformati on.
FUEL PUMP MODULE
Refer to the Fuel Pump Modul e for the 2.4/3.0/3.3/
3.8L engi nes i n the Fuel Del i very System secti on of
group 14.
ELECTRIC FUEL PUMP
Refer to the El ectri c Fuel Pump for the 2.4/3.0/3.3/
3.8L engi nes i n the Fuel Del i very System Secti on of
group 14 for more i nformati on.
FUEL LEVEL SENSOR
Refer to the Fuel Level Sensor for the 2.4/3.0/3.3/
Refer to the Fuel Pressure Regul ator for the 2.4/
3.0/3.3/3.8L engi nes i n the Fuel Del i very System sec-
ti on of group 14 for more i nformati on.
FUEL INJECTORS
Refer to the Fuel I njectors for the 2.4/3.0/3.3/3.8L
engi nes i n the Fuel Del i very System secti on of group
14 for more i nformati on.
FUEL TANK
Refer to the Fuel Tank for the 2.4/3.0/3.3/3.8L
PRESSURE-VACUUM FILLER CAP2. 0L ENGINE
Refer to the Pressure-Vacuum Fi l l er Cap for the
2.4/3.0/3.3/3.8L engi nes i n the Fuel Del i very System
secti on of group 14 for more i nformati on.
QUICK-CONNNECT FITTINGS2. 0L ENGINE
Refer to the Qui ck Connect Fi tti ngs for the 2.4/3.0/
3.3/3.8L engi nes i n the Fuel Del i very System secti on
of group 14 for more i nformati on.
FUEL PUMP PRESSURE TEST2. 0L ENGINE
Refer to the Fuel Pressure Test for the 2.4/3.0/3.3/
FUEL LEVEL SENSOR2. 0L ENGINE
Refer to the Fuel Level Sensor for the 2.4/3.0/3.3/
FUEL INJECTORS2. 0L ENGINE
Refer to the Fuel I njectors for the 2.4/3.0/3.3/3.8L
SERVICE PROCEDURES
PROCEDURE2. 0L ENGINE
Refer to the Fuel System Pressure Rel ease Proce-
dure for the 2.4/3.0/3.3/3.8L engi nes i n the Fuel
Del i very System secti on of group 14 for more i nfor-
mati on.
HOSES AND CLAMPS2. 0L ENGINE
Refer to Hoses and Cl amps for the 2.4/3.0/3.3/3.8L
QUICK-CONNNECT FITTINGS2. 0L ENGINE
Refer to the Qui ck Connect Fi tti ngs for the 2.4/3.0/
3.3/3.8L engi nes under Servi ce Procedures i n the
Fuel Del i very System secti on of group 14 for more
i nformati on.
FUEL FILTER2. 0L ENGINE
Refer to the Fuel Fi l ter for the 2.4/3.0/3.3/3.8L
engi nes under Removal and I nstal l ati on i n the Fuel
mati on.
FUEL PUMP MODULE2. 0L ENGINE
Refer to the Fuel Pump Modul e for the 2.4/3.0/3.3/
3.8L engi nes under Removal and I nstal l ati on i n the
Fuel Del i very System secti on of group 14 for more
i nformati on.
FUEL PRESSURE REGULATOR2. 0L ENGINE
Refer to the Fuel Pressure Rgul ator for the 2.4/3.0/
3.3/3.8L engi nes under Removal and I nstal l ati on i n
the Fuel Del i very System secti on of group 14 for
more i nformati on.
FUEL PRESSURE REGULATOR2. 0L ENGINE
Refer to the Fuel Pressure Regul ator for the 2.4/
3.0/3.3/3.8L engi nes under Removal and I nstal l ati on
i n the Fuel Del i very System secti on of group 14 for
more i nformati on.
Fig. 2 FUEL LEVEL SENSOR DIAGNOSIS
FUEL LEVEL SENSOR2. 0L ENGINE
Refer to the Fuel Pump I nl et Strai ner for the 2.4/
3.0/3.3/3.8L engi nes under Removal and I nstal l ati on
i n the Fuel Del i very System secti on of group 14 for
more i nformati on.
FUEL TANK2. 0L ENGINE
Refer to the Fuel Tank for the 2.4/3.0/3.3/3.8L
engi nes under Removal and I nstal l ati on i n the Fuel
mati on.
FUEL INJECTORS
REMOVAL
(2) Rel ease fuel system pressure. Refer to Fuel
System Pressure Rel ease procedure i n thi s secti on.
(3) Di sconnect fuel suppl y tube from rai l . Refer to
Qui ck-Connect Fi tti ngs i n the Fuel Del i very secti on
of thi s group.
(4) Di sconnect el ectri cal connectors from fuel i njec-
tors (Fi g. 4).
(5) Remove fuel rai l mounti ng screws.
(6) Li ft rai l off of i ntake mani fol d. Cover the fuel
i njector openi ngs i n the i ntake mani fol d.
(7) Remove fuel i njector retai ner (Fi g. 5).
(8) Pul l i njector out of fuel rai l . Repl ace fuel i njec-
tor O-ri ngs (Fi g. 6).
INSTALLATION
(1) Appl y a l i ght coati ng of cl ean engi ne oi l to the
upper O-ri ng.
(2) I nstal l i njector i n cup on fuel rai l .
(3) I nstal l retai ni ng cl i p.
(4) Appl y a l i ght coati ng of cl ean engi ne oi l to the
O-ri ng on the nozzl e end of each i njector.
(5) I nsert fuel i njector nozzl es i nto openi ngs i n
i ntake mani fol d. Seat the i njectors i n pl ace. Ti ghten
fuel rai l mounti ng screws to 22.5 Nm 3 Nm
(20030 i n. l bs.).
(6) Attach el ectri cal connectors to fuel i njectors.
Fig. 3 Fuel Pressure Test Port2.0L Fig. 4 Fuel Rail and Injectors
Fig. 5 Fuel Injector Retainer
Fig. 6 Fuel Injector O-Rings
(7) Connect fuel suppl y tube to fuel rai l . Refer to
Qui ck Connect Fi tti ngs i n the Fuel Del i very Secti on
of thi s Group.
ACCELERATOR PEDAL
Refer to the Accel erator Pedal for the 2.4/3.0/.3.3/
3.8L engi nes under Removal and I nstal l ati on i n the
Fuel Del i very secti on of group 14 for more i nforma-
ti on.
TORQUE SPECIFICATION
DESCRIPTION TORQUE
Accel erator Pedal to
Dash Nuts . . . . . . . . . . . . . . 12 Nm (105 i n. l bs.)
Fuel Pump Modul e Locknut . . . . 58 Nm (43 ft. l bs.)
Fuel Tank Strap Bol ts . . . . . . . . . 54 Nm (40 ft l bs.)
Fuel Rai l Bol ts . . . . . . . . . . . . . 23 Nm (195 i n. l bs.)
I gni ti on Coi l Mounti ng Bol ts . . . 11 Nm (95 i n. l bs.)
I ntake Mani fol d Bol ts . . . . . . . . 11 Nm (95 i n. l bs.)
Throttl e Control Shi el d . . . . . . . 5.6 Nm (50 i n. l bs.)
FUEL INJ ECTION SYSTEM2.0L ENGINE
INDEX
page page
GENERAL INFORMATION
INTRODUCTION2.0L ENGINE . . . . . . . . . . . . 32
MODES OF OPERATION2.0L ENGINE . . . . . 32
AIR CONDITIONING (A/C) RELAYPCM
OUTPUT2.0L ENGINE . . . . . . . . . . . . . . . . 35
AIR CONDITIONING PRESSURE
TRANSDUCERPCM INPUT
2.0L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . 33
AIR CONDITIONING SWITCH SENSE
PCM INPUT2.0L ENGINE . . . . . . . . . . . . . . 33
AUTOMATIC SHUTDOWN (ASD) SENSE
AUTOMATIC SHUTDOWN RELAY
PCM OUTPUT2.0L ENGINE . . . . . . . . . . . . 35
2.0L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . 33
DATA LINK CONNECTORPCM OUTPUT
2.0L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . 35
ELECTRONIC EGR TRANSDUCER
FUEL INJECTORSPCM OUTPUT
2.0L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . 35
FUEL PUMP RELAYPCM OUTPUT
2.0L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . 35
GENERATOR FIELDPCM OUTPUT
2.0L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . 35
HEATED OXYGEN SENSORPCM INPUT
2.0L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . 33
IDLE AIR CONTROL MOTORPCM OUTPUT
2.0L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . 35
IGNITION COILPCM OUTPUT
2.0L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . 36
KNOCK SENSORPCM INPUT
2.0L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . 34
LAMPPCM OUTPUT2.0L ENGINE . . . . . . 36
MANIFOLD ABSOLUTE PRESSURE
(MAP SENSOR)PCM INPUT
2.0L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . 34
2.0L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . 33
RADIATOR FAN CONTROL MODULE
SPEED CONTROL SOLENOIDS
SPEED CONTROLPCM INPUT
2.0L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . 34
STARTER RELAYPCM OUTPUT
2.0L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . 35
SYSTEM DIAGNOSIS2.0L ENGINE . . . . . . . . 33
2.0L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . 36
THROTTLE BODY2.0L ENGINE . . . . . . . . . . 36
THROTTLE POSITION SENSOR/ IDLE AIR
CONTROL MOTORPCM INPUT
2.0L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . 35
ASD AND FUEL PUMP RELAYS
2.0L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . 39
CAMSHAFT AND CRANKSHAFT
POSITION SENSOR . . . . . . . . . . . . . . . . . . . 40
SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
KNOCK SENSOR2.0L ENGINE . . . . . . . . . . . 40
MANIFOLD ABSOLUTE PRESSURE
(MAP) SENSOR2.0L ENGINE . . . . . . . . . . . 39
THROTTLE BODY MINIMUM AIR FLOW . . . . . 41
THROTTLE POSITION SENSOR . . . . . . . . . . . 40
VISUAL INSPECTIONSOHC . . . . . . . . . . . . . 36
SPECIFICATIONS
TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
GENERAL INFORMATION
INTRODUCTION2. 0L ENGINE
Refer to the I ntroducti on for 2.4/3.0/3.3/3.8L
engi nes under General I nformati on i n the Fuel I njec-
ti on System secti on of group 14 for more i nformati on.
MODES OF OPERATION2. 0L ENGINE
Refer to the Modes of Operati on for 2.4/3.0/3.3/3.8L
engi nes under General I nformati on i n the Fuel I njec-
SYSTEM DIAGNOSIS2. 0L ENGINE
Refer to System di agnosi s for 2.4/3.0/3.3/3.8L
engi nes under Descri pti on and Operati on i n the Fuel
I njecti on System secti on of group 14 for more i nfor-
mati on.
POWERTRAIN CONTROL MODULE2. 0L ENGINE
Refer to the Powertrai n Control Modul e for 2.4/3.0/
3.3/3.8L engi nes under Descri pti on and Operati on i n
the Fuel I njecti on System secti on of group 14 for
more i nformati on.
AIR CONDITIONING PRESSURE TRANSDUCER
PCM INPUT2. 0L ENGINE
Refer to the Ai r Condi ti oni ng Pressure Transducer
for 2.4/3.0/3.3/3.8L engi nes under Descri pti on and
Operati on i n the Fuel I njecti on System secti on of
AIR CONDITIONING SWITCH SENSEPCM
INPUT2. 0L ENGINE
Refer to the Ai r Condi ti oni ng Swi tch Sense for 2.4/
3.0/3.3/3.8L engi nes under Descri pti on and Operati on
i n the Fuel I njecti on System secti on of group 14 for
more i nformati on.
AUTOMATIC SHUTDOWN (ASD) SENSEPCM
INPUT2. 0L ENGINE
Refer to the Automati c Shutdown (ASD) Sense for
2.4/3.0/3.3/3.8L engi nes under Descri pti on and Oper-
ati on i n the Fuel I njecti on System secti on of group 14
for more i nformati on.
BATTERY VOLTAGEPCM INPUT2. 0L ENGINE
Refer to the Battery Vol tage for 2.4/3.0/3.3/3.8L
mati on.
CAMSHAFT POSITION SENSORPCM INPUT
2. 0L ENGINE
Refer to the Camshaft Posi ti on Sensor for 2.4L
engi ne under Descri pti on and Operati on i n the Fuel
mati on.
CRANKSHAFT POSITION SENSORPCM
INPUT2. 0L ENGINE
Refer to the Crankshaft Posi ti on Sensor for 2.4L
engi ne under Descri pti on and Operati on i n the Fuel
mati on.
INPUT2. 0L ENGINE
The cool ant temperature sensor threads i nto the
rear of the cyl i nder head, next to the camshaft posi -
ti on sensor (Fi g. 3). New sensors have seal ant
Refer to the Engi ne Cool ant Temperature Sensor
for the 2.4/3.0/3.3/3.8L engi nes under Descri pti on and
Operati on i n the Fuel I njecti on System secti on of
HEATED OXYGEN SENSORPCM INPUT2. 0L
ENGINE
Refer to the Heated Oxygen Sensor for 2.4/3.0/3.3/
3.8L engi nes under Descri pti on and Operati on i n the
Fuel I njecti on System secti on of group 14 for more
i nformati on.
Fig. 1 Camshaft Position Sensor2.0L Engine
Fig. 2 Crankshaft Posistion Sensor2.0L engine
KNOCK SENSORPCM INPUT2. 0L ENGINE
Refer to the Knock Sensor for 2.4/3.0/3.3/3.8L
mati on.
MANIFOLD ABSOLUTE PRESSURE (MAP
SENSOR)PCM INPUT2. 0L ENGINE
Refer to the Mani fol d Absol ute Pressure and
I ntake Ai r Temperature sensors for 2.4/3.0/3.3/3.8L
mati on.
SPEED CONTROLPCM INPUT2. 0L ENGINE
Refer to the Speed Control for 2.4/3.0/3.3/3.8L
mati on.
engine
Engine
Fig. 5 Downstream Heated Oxygen Sensor2.0L
Engine
Fig. 6 Knock Sensor2.0L engine
Fig. 7 MAP/IAT sensor2.0L engine
THROTTLE POSITION SENSOR/ IDLE AIR
CONTROL MOTORPCM INPUT2. 0L ENGINE
Refer to the Throttl e Control and I dl e Ai r Control
motor for the 2.4/3.0/3.3/3.8L engi nes under Descri p-
ti on and Operati on i n the Fuel I njecti on System sec-
ti on of group 14 for more i nformati on.
AIR CONDITIONING (A/C) RELAYPCM
OUTPUT2. 0L ENGINE
Refer to the Ai r Condi ti oni ng rel ay for 2.4/3.0/3.3/
i nformati on.
GENERATOR FIELDPCM OUTPUT2. 0L ENGINE
Refer to Generator Fi el d for 2.4/3.0/3.3/3.8L
mati on.
AUTOMATIC SHUTDOWN RELAYPCM
OUTPUT2. 0L ENGINE
Refer to Automati c Shutdown Rel ay for 2.4/3.0/3.3/
i nformati on.
FUEL PUMP RELAYPCM OUTPUT2. 0L ENGINE
Refer to the Fuel Pump Rel ay for 2.4/3.0/3.3/3.8L
mati on.
STARTER RELAYPCM OUTPUT2. 0L ENGINE
Refer to the Starter Rel ay for 2.4/3.0/3.3/3.8L
mati on.
IDLE AIR CONTROL MOTORPCM OUTPUT2. 0L
ENGINE
Refer to the I dl e Ai r Control Motor for 2.4/3.0/3.3/
i nformati on. Refer to (Fi g. 8) for component l ocati on
ELECTRONIC EGR TRANSDUCERPCM
OUTPUT2. 0L ENGINE
Refer to the El ectroni c EGR Transducer for 2.4/3.0/
3.3/3.8L engi nes under Descri pti on and Operati on i n
more i nformati on.
DATA LINK CONNECTORPCM OUTPUT2. 0L
ENGINE
Refer to the Data Li nk Connector for 2.4/3.0/3.3/
i nformati on.
FUEL INJECTORSPCM OUTPUT2. 0L ENGINE
Refer to the Fuel I njectors for 2.4/3.0/3.3/3.8L
mati on.
Fig. 8 Throttle Position Sensor/Idle Air Control
motor2.0L engine
Fig. 9 Electronic EGR Transducer2.0L engine
IGNITION COILPCM OUTPUT2. 0L ENGINE
Refer to the I gni ti on Coi l for 2.4/3.0/3.3/3.8L
mati on.
LAMPPCM OUTPUT2. 0L ENGINE
Refer to the Mal functi on I ndi cator Lamp for 2.4/
more i nformati on.
RADIATOR FAN CONTROL MODULEPCM
OUTPUT2. 0L ENGINE
Refer to the Radi ator Fan Control Modul e for 2.4/
more i nformati on.
SPEED CONTROL SOLENOIDSPCM OUTPUT
2. 0L ENGINE
Refer to the Speed Control Sol enoi ds for 2.4/3.0/3.3/
i nformati on.
TACHOMETERPCM OUTPUT2. 0L ENGINE
Refer to the Tachometer for 2.4/3.0/3.3/3.8L engi nes
under Descri pti on and Operati on i n the Fuel I njec-
THROTTLE BODY2. 0L ENGINE
Refer to the Throttl e Body for 2.4/3.0/3.3/3.8L
mati on.
VISUAL INSPECTIONSOHC
Before di agnosi ng or servi ci ng the fuel i njecti on
system, perform a vi sual i nspecti on for l oose, di scon-
nected, or mi srouted wi res and hoses. A thorough
vi sual i nspecti on that i ncl udes the fol l owi ng checks
saves unnecessary test and di agnosti c ti me.
(1) I nspect the battery connecti ons. Cl ean corroded
termi nal s.
(2) Check the 2 PCM 40-way connector for
stretched wi res on pushed out termi nal s
(3) Open the Power Di stri buti on Center (PDC).
Check for bl own fuses. Ensure the rel ays and fuses
are ful l y seated i n the PDC. A l abel on the undersi de
of the PDC cover shows the l ocati ons of each rel ay
and fuse.
(4) Veri fy the throttl e cabl e operates freel y.
(5) Check the el ectri cal connecti ons at the i dl e ai r
control motor and throttl e posi ti on sensor.
(6) Check hose connecti ons between the PCV
val ve, vacuum port - i ntake mani fol d and the oi l sep-
arator (Fi g. 13).
(7) I nspect the el ectri cal connecti ons at the MAP
sensor/i ntake ai r temperature sensor and the (Fi g.
14).
(8) I nspect the fuel i njector el ectri cal connecti ons
(Fi g. 15).
(9) I nspect the i gni ti on coi l el ectri cal connector.
Ensure the spark pl ug i nsul ators are fi rml y seated
over the spark pl ugs (Fi g. 16).
(10) Check the el ectri cal connecti on to the radi ator
fan.
(11) I nspect for corrosi on on the el ectri cal connec-
ti ons at the starter motor sol enoi d. Check the ground
cabl e connecti on bel ow the starter motor (Fi g. 17).
(12) I nspect the ai r cl eaner fi l ter el ement. Repl ace
as necessary. Check the ai r i nducti on system for
restri cti ons.
Fig. 10 Ignition Coil2.0L engine
Fig. 11 Throttle Body2.0L engine
(13) Check the el ectri cal connecti on at the knock
sensor (Fi g. 18).
(14) Check the el ectri cal connecti ons at the cam-
shaft posi ti on sensor and engi ne cool ant temperature
sensor (Fi g. 19).
(15) Check the el ectri cal connector at the El ec-
troni c EGR Transducer. I nspect the vacuum and back
pressure hoses at the sol enoi d and transducer for
l eaks (Fi g. 20).
(16) I nspect the el ectri cal connecti ons at the gen-
erator (Fi g. 21). Check the generator bel t for gl azi ng
or damage.
(17) I nspect the el ectri cal connector at the crank-
shaft posi ti on sensor (Fi g. 22).
(18) Check the el ectri cal connecti on at the vehi cl e
speed sensor (Fi g. 23).
Fig. 12 Idle Air Control Motor and Throttle Position
SensorTypical
Fig. 13 PCV Valve
Fig. 14 MAP/Intake Air Temperature Sensor
Fig. 15 Fuel Injectors
Fig. 16 Ignition Coil and Spark PlugsTypical
(19) Check the el ectri cal connecti on at the power
steeri ng pressure swi tch on the power steeri ng gear
Fig. 17 Starter Motor and Ground Strap
Fig. 19 Camshaft Position Sensor and Engine
Coolant Temperature Sensor
Fig. 20 Electronic EGR Transducer
Fig. 21 Generator
(20) I nspect the el ectri cal connecti ons at the
upstream and downstream heated oxygen sensors
(Fi g. 25) and (Fi g. 26).
(21) I nspect the fuel pump modul e el ectri cal con-
necti on at the fuel tank for corrosi on or damage (Fi g.
27). Check for pi nched, ki nked or damaged fuel sup-
pl y tube.
(22) I nspect the connecti ons to the speed control
servo, i f equi pped. Refer to Group 8H, Vehi cl e Speed
Control .
(23) I nspect the connecti on at the battery temper-
ature sensor.
ASD AND FUEL PUMP RELAYS2. 0L ENGINE
Refer to the ASD and Fuel Pump Rel ays for 2.4/
3.0/3.3/3.8L engi nes under Di agnosi s and Testi ng i n
more i nformati on.
SENSOR2. 0L ENGINE
To perform a compl ete test of the MAP sensor and
test the MAP sensor onl y, refer to the fol l owi ng:
Fig. 23 Vehicle Speed Sensor
Fig. 24 Power Steering Pressure Switch
Fig. 27 Fuel Pump Module Electrical Connector
CAUTION: When testing the MAP sensor, be sure
that the harness wires are not damaged by the test
meter probes.
(1) Test the MAP sensor output vol tage at the
MAP sensor connector between termi nal s 1 and 4
(Fi g. 29). Wi th the i gni ti on swi tch ON and the engi ne
not runni ng, output vol tage shoul d be 4 to 5 vol ts.
The vol tage shoul d drop to 1.5 to 2.1 vol ts wi th a hot,
neutral i dl e speed condi ti on. I f OK, go to next step. I f
not OK, go to step 3.
(2) Test PCM termi nal 36 for the same vol tage
descri bed i n the previ ous step to veri fy wi re harness
condi ti on. Repai r as requi red.
(3) Test the MAP sensor ground ci rcui t at sensor
connector termi nal 1 and PCM termi nal 43. I f OK, go
to next step. I f not OK, repai r as requi red.
(4) Test MAP sensor suppl y vol tage between sen-
sor connector termi nal s 3 and 1 wi th the key ON.
The vol tage shoul d be approxi matel y 5 vol ts (.5V).
Fi ve vol ts (.5V) shoul d al so be at termi nal 61 of the
PCM. I f OK, repl ace MAP sensor. I f not OK, repai r or
repl ace the wi re harness as requi red.
KNOCK SENSOR2. 0L ENGINE
The knock sensor output vol tage to the PCM can
be read wi th the DRB I I I scan tool . Sensor output
shoul d be between 80 mV and 4 vol ts wi th the engi ne
runni ng between 576 and 2208 rpm. I f the output
fal l s outsi de of thi s range a DTC wi l l be set.
CAMSHAFT AND CRANKSHAFT POSITION SENSOR
Refer to Group 8D, I gni ti on for Di agnosi s and Test-
i ng of Camshaft and Crankshaft Sensors.
Refer to the Engi ne Cool ant Temperature sensor
for the 2.4/3.0/3.3/3.8L engi nes under Di agnosi s and
Testi ng i n the Fuel I njecti on System secti on of group
i ts ci rcui try, the DRB I I I scan tool i s the best
method. To test the throttl e posi ti on sensor onl y,
refer to the fol l owi ng:
mi nal i s ground.
Fig. 29 MAP Sensor Connector
LocationSOHC
THROTTLE BODY MINIMUM AIR FLOW
(1) Turn i gni ti on key to Off.
(2) Di sconnect the PCV val ve hose from the i ntake
mani fol d ni ppl e (Fi g. 31). Cap the PCV vacuum ni ppl e.
(3) Di sconnect purge hose from the ni ppl e on the
(4) Use a pi ece of hose to attach Ai r Meteri ng Ori -
fi ce 6457 (0.125 i n. ori fi ce) to the purge ni ppl e on the
(5) Ensure that al l accessori es are off.
(6) Connect the DRB scan tool to the data l i nk
connector i nsi de the passenger compartment.
(7) Run engi ne i n Park or Neutral unti l the cool i ng
fan has cycl ed on and off at l east once (180F).
(8) Usi ng the DRB scan tool , access Mi ni mum Ai r-
fl ow I dl e Speed.
(9) The fol l owi ng wi l l then occur:
I dl e ai r control motor wi l l ful l y cl ose
I dl e spark advance wi l l become fi xed
PCM wi l l go open l oop enri ched
DRB scan tool di spl ays engi ne RPM
(10) I f i dl e RPM i s wi thi n the range shown i n the
I dl e Speci fi cati on chart, throttl e body mi ni mum ai r-
fl ow i s set correctl y.
IDLE SPECIFICATION 2.0L ENGINE
Bel ow 1000 Mi l es . . . . . . . . . . . . . . . 5501300 RPM
Above 1000 Mi l es . . . . . . . . . . . . . . . 6001300 RPM
(11) I f i dl e RPM i s above speci fi cati ons, use the
DRB scan tool to check i dl e ai r control motor opera-
ti on. I f i dl e ai r control motor i s OK, repl ace throttl e
body. I f i dl e ai r fl ow i s bel ow speci fi cati on, shut off
the engi ne and cl ean the throttl e body as fol l ows:
WARNING: CLEAN THROTTLE BODY IN A WELL
VENTILATED AREA. WEAR RUBBER OR BUTYL
GLOVES, DO NOT LET MOPAR PARTS CLEANER
COME IN CONTACT WITH EYES OR SKIN. AVOID
INGESTING THE CLEANER. WASH THOROUGHLY
AFTER USING CLEANER.
Fig. 31 PCV Vacuum Nipple
Fig. 32 Purge Hose
Fig. 33 Orifice 6457 Attached to Purge Nipple
(a) Remove the throttl e body from engi ne.
(b) Whi l e hol di ng the throttl e open, spray the
enti re throttl e body bore and the mani fol d si de of
the throttl e pl ate wi th Mopar Parts Cl eaner. Only
use Mopar Parts Cleaner to clean the throttle
body.
(c) Usi ng a soft scuff pad, cl ean the top and bot-
tom of throttl e body bore and the edges and mani -
fol d si de of the throttl e bl ade. The edges of the
throttle blade and portions of the throttle
bore that are closest to the throttle blade
when closed, must be free of deposits.
(d) Use compressed ai r to dry the throttl e body.
(e) I nspect throttl e body for forei gn materi al .
(f) I nstal l throttl e body on mani fol d.
(g) Repeat steps 1 through 14. I f the mi ni mum
ai r fl ow i s sti l l not wi thi n speci fi cati ons, the prob-
l em i s not caused by the throttl e body.
(13) Remove Ai r Meteri ng Ori fi ce 6457. I nstal l
purge hose.
(14) Remove cap from PCV val ve. Connect hose to
PCV val ve.
(15) Remove DRB scan tool .
SPECIFICATIONS
TORQUE
DESCRIPTION TORQUE
Ai r Cl eaner Wi ngnut . . . . . . . . . 1.5 Nm (15 i n. l bs.)
Ai r Cl eaner Mount. Stud-To-Thrott. Body . . 10 Nm
(90 i n. l bs.)
Crankshaft Posi ti on Sensor Mounti ng Bol ts . . 8 Nm
(70 i n. l bs.)
Engi ne Cool ant Temperature Sensor . . . . . . 18 Nm
(165 i n. l bs.)
I AC Motor-To-Throttl e Body Bol ts . . . . . . . . . 7 Nm
(60 i n. l bs.)
MAP/I AT Sensor . . . . . . . . . . . . . 2 Nm (20 i n. l bs.)
MAP/I AT Sensor . . . . . . . . . . . . . 3 Nm (30 i n. l bs.)
Oxygen Sensor . . . . . . . . . . . . . . 28 Nm (20 ft. l bs.)
(PCM) Mounti ng Screws . . . . . 4 Nm (35 i n. l bs.)
Throttl e Cabl e Cover . . . . . . . . 4.5 Nm (40 i n. l bs.).
Throttl e Body Mounti ng Bol ts . . . . . . . . . . . 23 Nm
(200 i n. l bs.)
Throttl e Posi ti on Sensor Mounti ng Screws . . . 2 Nm
(20 i n. l bs.)
Vehi cl e Speed Sensor Mounti ng Bol t . . . . . . 2.2 Nm
(20 i n. l bs.)
FUEL INJ ECTION SYSTEM2.5L DIESEL ENGINE
INDEX
page page
GENERAL INFORMATION
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . 43
AIR CONDITIONING (A/C) CONTROLS
PCM INPUTS . . . . . . . . . . . . . . . . . . . . . . . . 47
AIR CONDITIONING RELAYPCM OUTPUT . . 48
BATTERY VOLTAGEPCM INPUT . . . . . . . . . . 45
BOOST PRESSURE SENSOR . . . . . . . . . . . . . 45
BRAKE SWITCHPCM INPUT . . . . . . . . . . . . . 47
DATA LINK CONNECTOR
PCM INPUT AND OUTPUT . . . . . . . . . . . . . . 47
DIESEL PCM RELAYPCM INPUT . . . . . . . . . 48
ENGINE COOLANT GAUGEPCM OUTPUT . . 48
PCM INPUT . . . . . . . . . . . . . . . . . . . . . . . . . 46
ENGINE OIL PRESSURE GAUGE
PCM OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . 48
ENGINE SPEED SENSORPCM INPUT . . . . . 46
SOLENOIDPCM OUTPUT . . . . . . . . . . . . . 50
FIVE VOLT POWERPCM OUTPUT . . . . . . . . 48
FUEL INJECTOR SENSORGROUND . . . . . . 46
FUEL TIMING SOLENOIDPCM OUTPUT . . . . 48
GLOW PLUG LAMPPCM OUTPUT . . . . . . . . 48
GLOW PLUG RELAYPCM OUTPUT . . . . . . . 49
GLOW PLUGS . . . . . . . . . . . . . . . . . . . . . . . . . 49
IGNITION CIRCUIT SENSEPCM INPUT . . . . 45
NEEDLE MOVEMENT OR INSTRUMENTED
FIRST INJECTORPCM INPUT . . . . . . . . . . 45
POWER GROUND . . . . . . . . . . . . . . . . . . . . . . 45
POWERTRAIN CONTROL MODULE (PCM) . . . 44
SENSOR RETURNPCM INPUT (ANALOG
GROUND) . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
SIGNAL GROUNDPCM INPUT . . . . . . . . . . . 45
SPEED CONTROLPCM INPUTS . . . . . . . . . . 48
SPEED CONTROLPCM OUTPUTS . . . . . . . . 48
START SIGNALPCM INPUT . . . . . . . . . . . . . 45
TACHOMETERPCM OUTPUT . . . . . . . . . . . . 49
VEHICLE SPEED SENSORPCM INPUT . . . . 47
VEHICLE THEFT ALARM . . . . . . . . . . . . . . . . . 45
BOOST PRESSURE SENSOR . . . . . . . . . . . . . 53
DIAGNOSTIC TROUBLE CODES . . . . . . . . . . . 53
DIESEL DIAGNOSTICS . . . . . . . . . . . . . . . . . . 50
DIESEL PCM RELAY TEST . . . . . . . . . . . . . . . 50
SENSOR TEST . . . . . . . . . . . . . . . . . . . . . . . 50
ENGINE SPEED SENSOR TEST . . . . . . . . . . . 50
GLOW PLUG RELAY TEST . . . . . . . . . . . . . . . 51
GLOW PLUG TEST . . . . . . . . . . . . . . . . . . . . . 51
RELAYSOPERATION/TESTING . . . . . . . . . . . 52
VEHICLE SPEED SENSOR TEST . . . . . . . . . . . 53
A/C CLUTCH RELAY . . . . . . . . . . . . . . . . . . . . 53
DIESEL PCM RELAY . . . . . . . . . . . . . . . . . . . . 53
SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
ENGINE SPEED SENSOR . . . . . . . . . . . . . . . . 53
GLOW PLUG RELAY . . . . . . . . . . . . . . . . . . . . 55
GLOW PLUGS . . . . . . . . . . . . . . . . . . . . . . . . . 54
POWERTRAIN CONTROL MODULE (PCM) . . . 55
VEHICLE SPEED SENSOR . . . . . . . . . . . . . . . 55
SPECIFICATIONS
GLOW PLUG CURRENT DRAW . . . . . . . . . . . . 56
TORQUE CHART2.5L DIESEL . . . . . . . . . . . . 57
GENERAL INFORMATION
INTRODUCTION
Thi s secti on wi l l cover components ei ther regul ated
or control l ed by the Powertrai n Control Modul e
(PCM). The fuel heater rel ay, fuel heater and fuel
gauge are not operated by the PCM. These compo-
nents are control l ed by the i gni ti on (key) swi tch. Al l
other fuel system el ectri cal components necessary to
operate the engi ne are control l ed or regul ated by the
PCM. Refer to the fol l owi ng PCM descri pti on for
more i nformati on.
Certai n fuel system component fai l ures may cause
a no start, or prevent the engi ne from runni ng. I t i s
i mportant to know that the PCM has a feature
where, i f possi bl e, i t wi l l i gnore the fai l ed sensor, set
a code rel ated to the sensor, and operate the engi ne
i n a Li mp Home mode. When the PCM i s operati ng
i n a Li mp Home mode, the Di esel Gl ow Pl ug l amp
on the i nstrument panel wi l l be constantl y i l l umi -
nated, and the engi ne wi l l most l i kel y have a noti ce-
abl e l oss of performance. An exampl e of thi s woul d be
an Accel erator Pedal Posi ti on Sensor fai l ure, and i n
that si tuati on, the engi ne woul d run at a constant
1100 RPM, regardl ess of the actual posi ti on of the
pedal . Thi s i s the most extreme of the three Li mp
Home modes.
I n addi ti on to i ndi cati ng that the gl ow pl ugs are
hot enough to start combusti on, the Gl ow Pl ug Lamp
i s al so used i n the di agnosi s of the PCM, and when
i l l umi nated constantl y, i t usual l y i ndi cates a probl em
has been detected somewhere wi thi n the fuel system.
The DRBI I I scan tool i s the best method for commu-
ni cati ng wi th the PCM to di agnose faul ts wi thi n the
system.
The Powertrai n Control Modul e (PCM) i s mounted
i n the center consul e to a bracket l ocated i n front of
the Ai r Bag Modul e (Fi g. 1).
The PCM i s a preprogrammed, dual mi croproces-
sor di gi tal computer. I t wi l l ei ther di rectl y operate or
parti al l y regul ate the:
Speed Control
Speed Control LED l amp
Fuel Ti mi ng Sol enoi d
Gl ow Pl ug Rel ay
Gl ow Pl ugs
EGR Sol enoi d
Gl ow Pl ug Lamp
Di esel PCM Rel ay
Ai r Condi ti oni ng Operati on
Tachometer
Exhaust Gas Reci rcul ati on (EGR) Sol enoi d
The PCM can adapt i ts programmi ng to meet
changi ng operati ng condi ti ons.
The PCM recei ves i nput si gnal s from vari ous
swi tches and sensors. Based on these i nputs, the
PCM regul ates vari ous engi ne and vehi cl e operati ons
through di fferent system components. These compo-
nents are referred to as PCM Outputs. The sensors
and swi tches that provi de i nputs to the PCM are con-
si dered PCM Inputs.
PCM Inputs are:
Ai r Condi ti oni ng Sel ecti on
Theft Al arm
Cl utch Swi tch
Di esel PCM Rel ay
I SO-Protocol
Control Sl eeve
Fuel Temperature
Boost Pressure Sensor
Accel erator Pedal Sensor
EGR
A/C Pressure
Low I dl e Posi ti on Swi tch
5 Vol t Suppl y
Vehi cl e Speed Sensor
Sensor Return
Gl ow Pl ug
Engi ne Speed Sensor (rpm)
Fuel I njector #1 Sensor
Starter Si gnal
Brake Swi tch
Speed Control Swi tch Posi ti on
Power Ground
Si gnal Ground
I gni ti on (key) Swi tch Sense
Battery Vol tage
SCI Recei ve (DRB scan tool connecti on)
PCM Outputs:
After i nputs are recei ved by the PCM, certai n sen-
sors, swi tches and components are control l ed or reg-
ul ated by the PCM. These are consi dered PCM
Outputs. These outputs are for:
A/C Cl utch Rel ay (for A/C cl utch operati on)
Speed Control LED
Data Li nk Connectors (for DRB scan tool )
Di esel PCM Rel ay
Di esel PCM Sense
Accel arator Pedal
5 Vol ts Suppl y
Gl ow Pl ug Rel ay
Fan Rel ay
Fuel Quanti ty
Fuel Ti mi ng Sol enoi d
Fuel Shut-Off Sol enoi d
Engi ne Speed Sensor
Gl ow Pl ug Lamp (mal functi on i ndi cator l amp)
Exhaust Gas Reci rcul ati on (EGR) Sol enoi d
Gl ow Pl ug Rel ay
Tachometer
SCI transmi t (DRB scan tool connecti on)
Fig. 1 PCM Location
BOOST PRESSURE SENSOR
The Boost Pressure Sensor i s mounted to the top of
the i ntake mani fol d. (Fi g. 2) I t i s a sensor that mea-
sures both mani fol d vacuum and turbo boost, and i t
al so contai ns an i ntegrated i ntake ai r temperature
sensor. The Boost Pressure Sensor takes the pl ace of
the Mass Ai r Fl ow (MAF). I n the I ntake Ai r Temper-
ature Sensor component, there i s a cerami c el ement
that changes i ts resi stance based on temperature.
The cerami c el ement i s part of an el ectroni c ci rcui t
connected to the PCM, and has a vol tage appl i ed to
i t. The cerami c el ement i s exposed to the ai r i nsi de
the i ntake. Thi s ai r has a cool i ng effect on the
cerami c el ement, and i ts resi stance changes. Thi s
causes the vol tage fl owi ng through the i ntake ai r
temperature ci rcui t to vary. The vol tage si gnal pro-
duced by the I ntake Ai r Temperature Sensor changes
i nversel y to the temperature, and i s measured by the
PCM. As a general rul e, when the temperature of the
ai r i n the i ntake i s hi gh, the vol tage si gnal produced
by the I ntake Ai r Temperature Sensor i s l ow. The
component of the Boost Pressure Sensor that mea-
sures mani fol d vacuum and turbo boost produces a
vol tage si gnal that i s proporti onal to the pressure i n
the i nake mani fol d. When the i ntake mani fol d pres-
sure i s l ow, the vol tage i s l ow, and when the pressure
i s hi gh, the vol tage i s hi gh. The PCM uses the vol t-
age si gnal s from the Boost Pressure Sensor, and the
I ntake Ai r Temperature Sensor to determi ne the
amount of ai r fl owi ng through the i ntake mani fol d.
VEHICLE THEFT ALARM
The PCM can l earn i f the vehi cl e has a Vehi cl e
Theft Al arm (VTA) system. Once i t detects the vehi -
cl e havi ng VTA, the controller can ONLY BE
USED ON VEHICLES WITH VTA.
I f the PCM i s put i t on a vehi cl e wi thout VTA the
Gl ow Pl ug Lamp wi l l start to bl i nk and the vehi cl e
wi l l not start.
The PCM cannot be fl ashed to remove the VTA.
The battery vol tage i nput provi des power to the
PCM. I t al so i nforms the PCM what vol tage l evel i s
bei ng suppl i ed by the generator once the vehi cl e i s
runni ng.
The battery i nput al so provi des the vol tage that i s
needed to keep the PCM memory al i ve. The memory
stores Di agnosti c Troubl e Code (DTC) messages.
Troubl e codes wi l l sti l l be stored even i f the battary
vol tage i s l ost.
SENSOR RETURNPCM INPUT (ANALOG
GROUND)
Sensor Return provi des a l ow noi se Anal og ground
reference for al l system sensors.
SIGNAL GROUNDPCM INPUT
Si gnal ground provi des a l ow noi se ground to the
data l i nk connector.
IGNITION CIRCUIT SENSEPCM INPUT
The i gni ti on ci rcui t sense i nput si gnal s the PCM
that the i gni ti on (key) swi tch has been turned to the
ON posi ti on. Thi s si gnal i ni ti ates the gl ow pl ug con-
trol routi ne to begi n the preheat cycl e.
START SIGNALPCM INPUT
Thi s i nput tel l s the PCM that the engi ne starter i s
bei ng operated. Thi s i n turn wi l l start the gl ow pl ug
postheat cycl e.
POWER GROUND
Provi des a common ground for power devi ces (sol e-
noi d and rel ay devi ces).
NEEDLE MOVEMENT OR INSTRUMENTED FIRST
INJECTORPCM INPUT
Thi s i nput from the PCM suppl i es a constant 30
mA el ectri cal current source for the fi rst i njector sen-
sor. I t wi l l vary the vol tage to thi s sensor when i t
senses a mechani cal movement wi thi n the i njector
needl e (pi ntl e) of the number1 cyl i nder fuel i njector.
When thi s vol tage has been determi ned by the PCM,
i t wi l l then control an output to the fuel ti mi ng sol e-
noi d (the fuel ti mi ng sol enoi d i s l ocated on the fuel
i njecti on pump). Al so refer to Fuel I njecti on Pump for
addi ti onal i nformati on.
The fi rst i njector sensor i s a magneti c (i nducti ve)
type.
Fig. 2 Boost Pressure Sensor Location
The fi rst i njector sensor i s used onl y on the fuel
i njector for the number1 cyl i nder (Fi g. 3). I t i s not
used on the i njectors for cyl i nders number 2, 3, or 4.
FUEL INJECTOR SENSORGROUND
Provi des a l ow noi se ground for the fuel i njector
sensor onl y.
INPUT
The 05 vol t i nput from thi s sensor tel l s the PCM
the temperature of the engi ne cool ant. Based on the
vol tage recei ved at the PCM, i t wi l l then determi ne
operati on of the fuel ti mi ng sol enoi d, gl ow pl ug rel ay,
el ectri cal vacuum modul ator (emi ssi on component)
and generator (chargi ng system).
The sensor i s l ocated on the si de of the #3 cyl i nder
head near the rear of fuel i njecti on pump (Fi g. 4).
ENGINE SPEED SENSORPCM INPUT
The engi ne speed sensor i s mounted to the trans-
mi ssi on bel l housi ng at the l eft/rear si de of the engi ne
bl ock (Fi g. 5).
The engi ne speed sensor produces i ts own output
si gnal . I f thi s si gnal i s not recei ved the engi ne wi l l
not start by the PCM.
The engi ne speed sensor i nput i s used i n conjunc-
ti on wi th the fi rst i njector sensor to establ i sh fuel
i njecti on pump ti mi ng.
The fl ywheel has four notches at i ts outer edge
(Fi g. 6). Each notch i s spaced equal l y every 90. The
notches cause a pul se to be generated when they
pass under the speed sensor (Fi g. 6). These pul ses
are the i nput to the PCM. The i nput from thi s sensor
determi nes crankshaft posi ti on (i n degrees) by moni -
tori ng the notches.
The sensor al so generates an rpm si gnal to the
PCM. Thi s si gnal i s used as an i nput for the Di esel
rel ay for control of the generator fi el d, vehi cl e speed
control , and i nstrument panel mounted tachometer.
I f the engi ne speed sensor shoul d fai l , the system
i s unabl e to compensate for the probl em and the car
wi l l stop.
Fig. 4 Engine Coolant Temperature Sensor Location
Fig. 5 Engine Speed Sensor Location
AIR CONDITIONING (A/C) CONTROLSPCM
INPUTS
The A/C control system i nformati on appl i es to fac-
tory i nstal l ed ai r condi ti oni ng uni ts.
A/C REQUEST SIGNAL: When ei ther the A/C or
Defrost mode has been sel ected and the A/C l ow and
hi ghpressure swi tches are cl osed, an i nput si gnal i s
sent to the powertrai n control modul e (PCM). The
PCM uses thi s i nput to cycl e the A/C compressor
through the A/C rel ay.
I f the A/C l ow or hi ghpressure swi tch opens, the
PCM wi l l not recei ve an A/C request si gnal . The
PCM wi l l then remove the ground from the A/C rel ay.
Thi s wi l l deacti vate the A/C compressor cl utch. Al so,
i f the engi ne cool ant reaches a temperature outsi de
normal of i ts normal range, or i t overheats, the PCM
wi l l deacti vate the A/C cl utch.
BRAKE SWITCHPCM INPUT
When the brake l i ght swi tch i s acti vated, the PCM
recei ves an i nput i ndi cati ng that the brakes are
bei ng appl i ed. After recei vi ng thi s i nput, the PCM i s
used to control the speed control system. There i s a
Pri mary and a Secondary brake swi tch. The Second-
ary brake swi tch i s cl osed unti l the brake pedal i s
pressed.
DATA LINK CONNECTORPCM INPUT AND
OUTPUT
The 16way data l i nk connector (di agnosti c scan
tool connector) l i nks the Di agnosti c Readout Box
(DRB) scan tool wi th the PCM. The data l i nk connec-
tor i s l ocated under the i nstrument panel near the
bottom of steeri ng col umn (Fi g. 7).
VEHICLE SPEED SENSORPCM INPUT
The vehi cl e speed sensor (Fi g. 8) i s l ocated i n the
extensi on housi ng of the transmi ssi on. The sensor
i nput i s used by the PCM to determi ne vehi cl e speed
and di stance travel ed.
Fig. 6 Speed Sensor Operation
Fig. 7 Data Link Connector Location
Fig. 8 Vehicle Speed SensorTypical
The speed sensor generates 8 pul ses per sensor
revol uti on. These si gnal s, i n conjuncti on wi th a
cl osed throttl e si gnal from the throttl e posi ti on sen-
sor, i ndi cate a cl osed throttl e decel erati on to the
PCM. When the vehi cl e i s stopped at i dl e, a cl osed
throttl e si gnal i s recei ved by the PCM (but a speed
sensor si gnal i s not recei ved).
I n addi ti on to determi ni ng di stance and vehi cl e
speed, the output from the sensor i s used to control
speed control operati on.
SPEED CONTROLPCM INPUTS
The speed control system provi des fi ve separate
i nputs to the PCM; On/Off, Set, Resume/Accel , Cancel ,
and Decel .. The On/Off i nput i nforms the PCM that
the speed control system has been acti vated. The Set
i nput i nforms the PCM that a fi xed vehi cl e speed has
been sel ected. The Resume i nput i ndi cates to the PCM
that the previ ous fi xed speed i s requested.
Speed control operati on wi l l start at 50 km/h142
km/h (3585 mph). The upper range of operati on i s
not restri cted by vehi cl e speed. I nputs that affect
speed control operati on are vehi cl e speed sensor and
throttl e posi ti on sensor.
Refer to Group 8H for further speed control i nfor-
mati on.
DIESEL PCM RELAYPCM INPUT
A 12 vol t si gnal at thi s i nput i ndi cates to the PCM
that the Di esel rel ay has been acti vated. The Di esel
rel ay i s l ocated i n the PDC. The PDC i s l ocated next
to the battery i n the engi ne compartment. For the
l ocati on of the rel ay wi thi n the PDC, refer to l abel on
PDC cover.
Thi s i nput i s used onl y to sense that the Di esel
rel ay i s energi zed. I f the PCM does not see 12 vol ts +
at thi s i nput when the Di esel rel ay shoul d be acti -
vated, i t wi l l set a Di agnosti c Troubl e Code (DTC).
FIVE VOLT POWERPCM OUTPUT
Thi s ci rcui t suppl i es approxi matel y 5 vol ts to
power the Accel erator Pedal Posti on Sensor, Mass Ai r
Fl ow Sensor, and A/C Pressure Sensor.
ENGINE COOLANT GAUGEPCM OUTPUT
Refer to the I nstrument Panel and Gauges group
for addi ti onal i nformati on.
ENGINE OIL PRESSURE GAUGEPCM OUTPUT
Refer to the I nstrument Panel and Gauges group
for addi ti onal i nformati on.
GLOW PLUG LAMPPCM OUTPUT
The Gl ow Pl ug l amp (mal functi on i ndi cator l amp)
i l l umi nates on the message center each ti me the i gni -
ti on (key) swi tch i s turned on. I t wi l l stay on for
about two seconds as a bul b test.
I f the PCM recei ves an i ncorrect si gnal , or no si g-
nal from certai n sensors or components, the l amp
BLI NKS. Thi s i s a warni ng that the PCM has
recorded a system or sensor mal functi on. I t si gnal s
an i mmedi ate need for servi ce. There are onl y 5
HARD faul ts that can turn on thi s l amp to make i t
bl i nk.
SPEED CONTROLPCM OUTPUTS
These two ci rcui ts control the fuel quanti ty actua-
tor to regul ate vehi cl e speed. Refer to Group 8H for
Speed Control i nformati on.
AIR CONDITIONING RELAYPCM OUTPUT
Thi s ci rcui t control s a ground si gnal for operati on
of the A/C cl utch rel ay. Al so refer to Ai r Condi ti oni ng
(A/C) Control sPCM I nput for addi ti onal i nforma-
ti on.
The A/C rel ay i s l ocated i n the Power Di stri buti on
Center (PDC). The PDC i s l ocated next to the battery
i n the engi ne compartment. For the l ocati on of the
rel ay wi thi n the PDC, refer to l abel on PDC cover.
FUEL TIMING SOLENOIDPCM OUTPUT
The fuel ti mi ng sol enoi d i s l ocated on the bottom of
the fuel i njecti on pump (Fi g. 10).
Thi s 12+ vol t, pul se wi dth modul ated (dutycycl e)
output control s the amount of fuel ti mi ng (advance)
i n the fuel i njecti on pump. The hi gher the duty-
Fig. 9 Glow Plug Lamp Symbol
Fig. 10 Fuel Timing Solenoid
cycl e, the l ower the advance. The l ower the duty-
cycl e, the more advanced the fuel ti mi ng.
The dutycycl e i s determi ned by the PCM from
i nputs i t recei ves from the fuel i njector sensor and
engi ne speed sensor.
The PCM suppl i es engi ne rpm val ues to the Body
Control l er that then suppl i es the i nstrument cl uster
mounted tachometer (i f equi pped). Refer to Group 8E
for tachometer i nformati on.
GLOW PLUG RELAYPCM OUTPUT
The gl ow pl ug rel ay i s l ocated i n the engi ne com-
partment on the l efti nner fender (Fi g. 11).
When the i gni ti on (key) swi tch i s pl aced i n the ON
posi ti on, a si gnal i s sent to the PCM rel ati ng current
engi ne cool ant temperature. Thi s si gnal i s sent from
the engi ne cool ant temperature sensor.
After recei vi ng thi s si gnal , the PCM wi l l determi ne
i f, when and for how l ong a peri od the gl ow pl ug
rel ay shoul d be acti vated. Thi s i s done before, duri ng
and after the engi ne i s started. Whenever the gl ow
pl ug rel ay i s acti vated, i t wi l l control the 12V+ 100
amp ci rcui t for the operati on of the four gl ow pl ugs.
The Gl ow Pl ug l amp i s ti ed to thi s ci rcui t. Lamp
operati on i s al so control l ed by the PCM.
Wi th a col d engi ne, the gl ow pl ug rel ay and gl ow
pl ugs may be acti vated for a maxi mum ti me of 200
seconds. Refer to the fol l owi ng Gl ow Pl ug Control
chart for a temperature/ti me compari son of gl ow pl ug
rel ay operati on.
I n thi s chart, PreHeat and PostHeat ti mes are
menti oned. Preheat i s the amount of ti me the gl ow
pl ug rel ay ci rcui t i s acti vated when the i gni ti on (key)
swi tch i s ON, but the engi ne has yet to be started.
Postheat i s the amount of ti me the gl ow pl ug rel ay
ci rcui t i s acti vated after the engi ne i s operati ng. The
Gl ow Pl ug l amp wi l l not be i l l umi nated duri ng the
postheat cycl e.
GLOW PLUGS
Gl ow pl ugs are used to hel p start a col d or cool
engi ne. The pl ug wi l l heat up and gl ow to heat the
combusti on chamber of each cyl i nder. An i ndi vi dual
pl ug i s used for each cyl i nder. Each pl ug i s threaded
i nto the cyl i nder head above the fuel i njector (Fi g. 12).
Each pl ug wi l l momentari l y draw approxi matel y 25
amps of el ectri cal current duri ng the i ni ti al keyon
cycl e. Thi s i s on a col d or cool engi ne. After heati ng,
GLOW PLUG CONTROL
Fig. 12 Glow Plug
the current draw wi l l drop to approxi matel y 912
amps per pl ug.
Total momentary current draw for al l four pl ugs i s
approxi matel y 100 amps on a col d engi ne droppi ng to
a total of approxi matel y 40 amps after the pl ugs are
heated.
El ectri cal operati on of the gl ow pl ugs are con-
trol l ed by the gl ow pl ug rel ay. Refer to the previ ous
Gl ow Pl ug Rel ayPCM Output for addi ti onal i nfor-
mati on.
SOLENOIDPCM OUTPUT
Thi s ci rcui t control s operati on of the Exhaust Gas
Reci rcul ati on (EGR) sol enoi d. The EGR sol enoi d (Fi g.
11) control s operati on of the EGR val ve.
Refer to Group 25, Emi ssi on Control System for
i nformati on. See EGR sol enoi d.
DIESEL DIAGONSTICS
The PCM control l er does engi ne off di agonsti cs
tests, whi ch may be heard for about 60 seconds after
turni ng the key off.
DIESEL PCM RELAY TEST
To perform a test of the rel ay and i ts rel ated ci r-
cui try, refer to the DRB scan tool . To test the rel ay
onl y, refer to Rel aysOperati on/Testi ng i n thi s sec-
ti on of the group.
ENGINE SPEED SENSOR TEST
To perform a test of the engi ne speed sensor and
i ts rel ated ci rcui try, refer to the DRB scan tool .
ENGINE COOLANT TEMPERATURE SENSOR TEST
For a l i st of Di agnosti c Troubl e Codes (DTCs) for
certai n fuel system components, refer to On-Board
Di agnosti cs i n Group 25, Emi ssi on Control System.
To test the sensor onl y, refer to the fol l owi ng:
(1) Di sconnect wi re harness connector from cool ant
temperature sensor.
(2) Test the resi stance of the sensor wi th a hi gh
i nput i mpedance (di gi tal ) vol tohmmeter. The resi s-
tance (as measured across the sensor termi nal s)
shoul d be l ess than 1340 ohms wi th the engi ne
warm. Refer to the fol l owi ng Sensor Resi stance
(OHMS) chart. Repl ace the sensor i f i t i s not wi thi n
the range of resi stance speci fi ed i n the chart.
(3) Test conti nui ty of the wi re harness. Do thi s
between the PCM wi re harness connector and the
sensor connector termi nal . Al so test conti nui ty of
wi re harness to the sensor connector termi nal . Refer
Location
SENSOR RESISTANCE (OHMS)
to Group 8W for wi ri ng connector and ci rcui try i nfor-
mati on. Repai r the wi re harness i f an open ci rcui t i s
i ndi cated.
(4) After tests are compl eted, connect el ectri cal
connector to sensor.
GLOW PLUG TEST
Hard starti ng or a rough i dl e after starti ng may be
caused by one or more defecti ve gl ow pl ugs. Before
testi ng the gl ow pl ugs, a test of the gl ow pl ug rel ay
shoul d be performed. Thi s wi l l ensure that 12V+ i s
avai l abl e at the pl ugs when starti ng the engi ne.
Refer to the Gl ow Pl ug Rel ay Test for i nformati on.
For accurate test resul ts, the gl ow pl ugs shoul d be
removed from the engi ne. The pl ugs must be checked
when col d. Do not check the plugs if the engine
has recently been operated. If plugs are
checked when warm, incorrect amp gauge
readings will result.
Use Churchi l l Gl ow Pl ug Tester DX.900 or an
equi val ent (Fi g. 14) for the fol l owi ng tests. Thi s
tester i s equi pped wi th 4 ti mer l amps.
(1) Remove the gl ow pl ugs from the engi ne. Refer
to Gl ow Pl ug Removal /I nstal l ati on.
(2) Attach the red l ead of the tester to the 12V+
(posi ti ve) si de of the battery.
(3) Attach the bl ack l ead of the tester to the 12V
(negati ve) si de of the battery.
(4) Fi t the gl ow pl ug i nto the top of the tester and
secure i t wi th the spri ng l oaded bar (Fi g. 14).
(5) Attach the thi rd l ead wi re of the tester to the
el ectri cal termi nal at the end of the gl ow pl ug.
(6) When performi ng the test, the tester button
(Fi g. 14) shoul d be hel d conti nuousl y wi thout rel ease
for 20 seconds as i ndi cated by the 4 ti mer l amps.
Each i l l umi nated l amp represents a 5 second ti me
l apse.
(a) Press and hol d the tester button (Fi g. 14)
and note the amp gauge readi ng. The gauge read-
i ng shoul d i ndi cate a momentary, i ni ti al current
draw (surge) of approxi matel y 25 amps. After the
i ni ti al surge, the amp gauge readi ng shoul d begi n
to fal l off. The gl ow pl ug ti p shoul d start to gl ow
an orange col or after 5 seconds. I f the ti p di d not
gl ow after 5 seconds, repl ace the gl ow pl ug. Before
di scardi ng the gl ow pl ug, check the posi ti on of the
ci rcui t breaker on the bottom of the pl ug tester. I t
may have to be reset. Reset i f necessary.
(b) Conti nue to hol d the tester button whi l e
observi ng the amp gauge and the 4 ti mer l amps.
When al l 4 l amps are i l l umi nated, i ndi cati ng a 20
second ti me l apse, the amp gauge readi ng shoul d
i ndi cate a 912 amp current draw. I f not, repl ace
the gl ow pl ug. Refer to Gl ow Pl ug Removal /I nstal -
l ati on.
(7) Check each gl ow pl ug i n thi s manner usi ng one
20 second cycl e. I f the gl ow pl ug i s to be retested, i t
must fi rst be al l owed to cool to room temperature.
WARNING: THE GLOW PLUG WILL BECOME
EXTREMELY HOT (GLOWING) DURING THESE
TESTS. BURNS COULD RESULT IF IMPROPERLY
HANDLED. ALLOW THE GLOW PLUG TO COOL
BEFORE REMOVING FROM TESTER.
(8) Remove the gl ow pl ug from the tester.
GLOW PLUG RELAY TEST
When the i gni ti on (key) swi tch i s pl aced i n the ON
posi ti on, a si gnal i s sent to the PCM rel ati ng current
engi ne cool ant temperature. Thi s si gnal i s sent from
the engi ne cool ant temperature sensor.
After recei vi ng thi s si gnal , the PCM wi l l deter-
mi ne i f, when and for how l ong a peri od the gl ow
pl ug rel ay shoul d be acti vated. Thi s i s done before,
duri ng and after the engi ne i s started. Whenever the
gl ow pl ug rel ay i s acti vated, i t wi l l control the 12V+
100 amp ci rcui t for the operati on of the four gl ow
pl ugs.
The Gl ow Pl ug l amp i s ti ed to thi s ci rcui t. Lamp
operati on i s al so control l ed by the PCM.
Wi th a col d engi ne, the gl ow pl ug rel ay and gl ow
pl ugs may be acti vated for a maxi mum ti me of 200
seconds. Refer to the Gl ow Pl ug Control chart for a
temperature/ti me compari son of gl ow pl ug rel ay oper-
ati on.
Fig. 14 Typical Glow Plug Tester
I n thi s chart, PreHeat and PostHeat ti mes are
menti oned. Preheat i s the amount of ti me the gl ow
pl ug rel ay ci rcui t i s acti vated when the i gni ti on (key)
swi tch i s ON, but the engi ne has yet to be started.
Postheat i s the amount of ti me the gl ow pl ug rel ay
ci rcui t i s acti vated after the engi ne i s operati ng. The
Gl ow Pl ug l amp wi l l not be i l l umi nated duri ng the
postheat cycl e.
TESTING:
Di sconnect and i sol ate the el ectri cal connectors
(Fi g. 16) at al l four gl ow pl ugs. Wi th the engi ne cool
or col d, and the key i n the ON posi ti on, check for
1012 vol ts + at each el ectri cal connector. 1012 vol ts
+ shoul d be at each connector whenever the PCM i s
operati ng i n the preheat or postheat cycl es (refer
to the fol l owi ng Gl ow Pl ug Control chart). Be very
careful not to allow any of the four discon-
nected glow plug electrical connectors to con-
tact a metal surface. When the key is turned to
the ON position, approximately 100 amps at 12
volts is supplied to these connectors. I f 1012
vol ts + i s not avai l abl e at each connector, check con-
ti nui ty of wi ri ng harness di rectl y to the rel ay. I f con-
ti nui ty i s good di rectl y to the rel ay, the faul t i s ei ther
wi th the rel ay or the rel ay i nput from the PCM. To
test the rel ay onl y, refer to Rel aysOperati on/Test-
i ng i n thi s secti on of the group. I f the rel ay test i s
good, refer to the DRB scan tool .
RELAYSOPERATION/TESTING
The following description of operation and
tests apply only to the Diesel PCM and other
relays. The termi nal s on the bottom of each rel ay
are numbered (Fi g. 17).
OPERATION
Termi nal number 30 i s connected to battery vol t-
age. For both the Di esel and other rel ays, termi nal
30 i s connected to battery vol tage at al l ti mes.
The PCM grounds the coi l si de of the rel ay
through termi nal number 85.
Termi nal number 86 suppl i es vol tage to the coi l
si de of the rel ay.
When the PCM de-energi zes the Di esel PCM
and other rel ays, termi nal number 87A connects to
termi nal 30. Thi s i s the Off posi ti on. I n the off posi -
ti on, vol tage i s not suppl i ed to the rest of the ci rcui t.
Termi nal 87A i s the center termi nal on the rel ay.
Fig. 16 Wiring Connection at Glow Plug
GLOW PLUG CONTROL
When the PCM energi zes the Di esel PCM and
other rel ays, termi nal 87 connects to termi nal 30.
Thi s i s the On posi ti on. Termi nal 87 suppl i es vol tage
to the rest of the ci rcui t.
TESTING
The fol l owi ng procedure appl i es to the Di esel PCM
and other rel ays.
(1) Remove rel ay from connector before testi ng.
(2) Wi th the rel ay removed from the vehi cl e, use
an ohmmeter to check the resi stance between termi -
nal s 85 and 86. The resi stance shoul d be between 75
5 ohms.
and 87A. The ohmmeter shoul d show conti nui ty
between termi nal s 30 and 87A.
and 30. The ohmmeter shoul d not show conti nui ty at
thi s ti me.
(5) Connect one end of a jumper wi re (16 gauge or
smal l er) to rel ay termi nal 85. Connect the other end
of the jumper wi re to the ground si de of a 12 vol t
power source.
(6) Connect one end of another jumper wi re (16
gauge or smal l er) to the power si de of the 12 vol t
power source. Do not attach the other end of the
jumper wire to the relay at this time.
WARNING: DO NOT ALLOW OHMMETER TO CON-
TACT TERMINALS 85 OR 86 DURING THIS TEST.
(7) Attach the other end of the jumper wi re to
rel ay termi nal 86. Thi s acti vates the rel ay. The ohm-
meter shoul d now show conti nui ty between rel ay ter-
mi nal s 87 and 30. The ohmmeter shoul d not show
conti nui ty between rel ay termi nal s 87A and 30.
(8) Di sconnect jumper wi res.
(9) Repl ace the rel ay i f i t di d not pass the conti nu-
i ty and resi stance tests. I f the rel ay passed the tests,
i t operates properl y. Check the remai nder of the Di e-
sel PCM and other rel ay ci rcui ts. Refer to group 8W,
Wi ri ng Di agrams.
BOOST PRESSURE SENSOR
I f the boost pressure sensor fai l s, the PCM records
a DTC i nto memory and conti nues to operate the
engi ne i n one of the three l i mp-i n modes. When the
PCM i s operati ng i n thi s mode, a l oss of power wi l l
be present, as i f the turbocharger was not operati ng.
The best method for di agnosi ng faul ts wi th the boost
pressure sensor i s wi th the DRB I I I scan tool .
VEHICLE SPEED SENSOR TEST
To perform a test of the sensor and i ts rel ated ci r-
cui try, refer to DRB scan tool .
For a l i st of Di agnosti c Troubl e Codes (DTCs),
refer to Group 25, Emi ssi on Control System for i nfor-
mati on. See On-Board Di agnosti cs.
DIESEL PCM RELAY
The Di esel PCM rel ay i s l ocated i n the PDC. For
the l ocati on of the rel ay wi thi n the PDC, refer to
l abel on PDC cover.
A/C CLUTCH RELAY
The A/C cl utch rel ay i s l ocated i n the PDC. For the
l ocati on of the rel ay wi thi n the PDC, refer to l abel on
PDC cover.
ENGINE SPEED SENSOR
The engi ne speed sensor i s mounted to the trans-
mi ssi on bel l housi ng at the rear of the engi ne bl ock
(Fi g. 18).
REMOVAL
(1) Di sconnect the harness (on the sensor) from
the mai n el ectri cal harness.
Fig. 17 Diesel PCM and Other Relay Terminals
(2) Remove the sensor mounti ng bol ts.
(3) Remove the sensor.
INSTALLATION
(1) I nstal l the sensor fl ush agai nst the openi ng i n
the transmi ssi on housi ng.
(2) I nstal l and ti ghten the sensor mounti ng bol t to
19 Nm (14 ft. l bs.) torque.
(3) Connect the el ectri cal connector to the sensor.
REMOVAL
REFER TO GROUP 7, COOLING.
(1) Parti al l y drai n cool i ng system. Refer to Group
7, Cool i ng.
(3) Remove sensor from cyl i nder head.
INSTALLATION
(1) I nstal l a new copper gasket to sensor.
(2) I nstal l sensor to cyl i nder head.
(3) Ti ghten sensor to 18 Nm (13 ft. l bs.) torque.
(5) Repl ace any l ost engi ne cool ant. Refer to Group
7, Cool i ng System.
GLOW PLUGS
The gl ow pl ugs are l ocated above each fuel i njector
(Fi g. 20). Four i ndi vi dual pl ugs are used.
REMOVAL
(1) Di sconnect the negati ve battery cabl e at the
battery.
(2) Cl ean the area around the gl ow pl ug wi th com-
pressed ai r before removal .
(3) Di sconnect el ectri cal connector (Fi g. 21) at gl ow
pl ug.
(4) Remove the gl ow pl ug (Fi g. 20) from cyl i nder
head.
Fig. 18 Engine Speed Sensor Fig. 19 Engine Coolant Temperature Sensor
Location
Fig. 20 Glow Plug
INSTALLATION
(1) Appl y hi ghtemperature anti sei ze compound
to gl ow pl ug threads before i nstal l ati on
(2) I nstal l the gl ow pl ug i nto the cyl i nder head.
Ti ghten to 23 Nm (203 i n. l bs.) torque.
(3) Connect battery cabl e to battery.
GLOW PLUG RELAY
REMOVAL
battery.
(2) Remove rel ay mounti ng bol t.
(3) Di sconnect el ectri cal connector at rel ay and
remove rel ay.
INSTALLATION
(1) Check condi ti on of el ectri cal connector for dam-
age or corrosi on. Repai r as necessary.
(2) I nstal l el ectri cal connector to rel ay.
(3) I nstal l rel ay to i nner fender.
(4) Connect battery cabl e to battery.
The PCM i s mounted to a bracket l ocated i n the
center consul e i n front of the ai r bag modul e (Fi g.
23).
REMOVAL
battery.
(2) Loosen the 68Way connector (Fi g. 23). The
el ectri cal connector has a sl i di ng bar whi ch moves
i nward to l ock or outward to unl ock.
(3) Remove the el ectri cal connector by pul l i ng
strai ght out.
(4) Remove PCM.
INSTALLATION
(1) After the PCM el ectri cal connector has been
separated from the PCM, i nspect the pi ns for corro-
si on, bei ng spread apart, bent or mi sal i gned. Al so
i nspect the pi n hei ghts i n the connector. I f the pi n
hei ghts are di fferent, thi s woul d i ndi cate a pi n has
separated from the connector. Repai r as necessary.
(2) Engage 68way connector i nto PCM. Move
sl i de bar to l ock connector.
The vehi cl e speed sensor (Fi g. 24) i s l ocated on the
extensi on housi ng of the transmi ssi on.
Fig. 21 Glow Plug Electrical Connector
Fig. 23 PCM Location
REMOVAL
(2) Cl ean the area around the sensor before
removal .
sensor (Fi g. 25).
(4) Remove the sensor mounti ng bol t (Fi g. 25).
(5) Pul l the sensor from the speedometer pi ni on
gear adapter for removal .
INSTALLATION
(1) I nstal l new sensor i nto speedometer gear
adapter.
(2) Ti ghten sensor mounti ng bol t. To prevent dam-
age to sensor or speedometer adapter, be sure the
sensor i s mounted fl ush to the adapter before ti ght-
eni ng.
SPECIFICATIONS
GLOW PLUG CURRENT DRAW
Initial Current Draw: Approxi matel y 2225
amps per pl ug.
After 20 seconds of operation: Approxi matel y
912 amps per pl ug.
Fig. 25 Sensor Removal/InstallationTypical
Fig. 24 Vehicle Speed Sensor LocationTypical
TORQUE CHART2. 5L DIESEL
STEERING
CONTENTS
page page
POWER STEERING GEAR . . . . . . . . . . . . . . . . . . 26
POWER STEERING PUMP . . . . . . . . . . . . . . . . . . 9
STEERING COLUMN . . . . . . . . . . . . . . . . . . . . . . 36
GENERAL INFORMATION
INDEX
page page
GENERAL INFORMATION
STEERING SYSTEM AND COMPONENT
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 1
STEERING SYSTEM DIAGNOSIS CHARTS . . . . . 2
GENERAL INFORMATION
STEERING SYSTEM AND COMPONENT
DESCRIPTION
The power steeri ng system consi sts of these four
major components. Power Steeri ng Pump, Power
Steeri ng Gear, Pressure Hose, and Return Li ne.
Turni ng of the steeri ng wheel i s converted i nto l i near
travel through the meshi ng of the hel i cal pi ni on
teeth wi th the rack teeth. Power assi st steeri ng i s
provi ded by an open center, rotary type control val ve.
I t i s used to di rect oi l from the pump to ei ther si de of
the i ntegral steeri ng rack pi ston.
Road feel i s control l ed by the di ameter of a torsi on
bar whi ch i ni ti al l y steers the vehi cl e. As requi red
steeri ng effort i ncreases, as i n a turn, the torsi on bar
twi sts, causi ng rel ati ve rotary moti on between the
rotary val ve body and the val ve spool . Thi s move-
ment di rects oi l behi nd the i ntegral rack pi ston,
whi ch, i n turn, bui l ds up hydraul i c pressure and
assi sts i n the turni ng effort.
Dri ve tangs on the power steeri ng gear pi ni on
shaft, mate l oosel y wi th the shaft of the steeri ng
gear. Thi s i s to al l ow manual steeri ng control to be
mai ntai ned, i f the dri ve bel t on the power steeri ng
pump shoul d break. However, under these condi ti ons,
steeri ng effort wi l l si gni fi cantl y i ncrease.
NS STEERING 19 - 1
STEERING SYSTEM DIAGNOSIS CHARTS
STEERING NOISE
There i s some noi se i n al l power steeri ng systems. One of the most common i s a hi ssi ng sound evi dent at
standsti l l parki ng. Hi ss i s a very hi gh frequency noi se si mi l ar to that experi enced whi l e sl owl y cl osi ng a water
tap. The noi se i s present i n every val ve and resul ts from hi gh vel oci ty fl ui d passi ng over the edges of the val ve
ori fi ce. There i s no rel ati onshi p between thi s noi se and the performance of the vehi cl es steeri ng system. Hi ss
may be expected when the steeri ng wheel i s at the end of i ts travel or sl owl y turni ng when the vehi cl e i s at
a standsti l l .
Objectionable Hiss Or Whistle 1. Damaged or mispositioned
steering column coupler to dash
panel seal.
1. Check for proper seal between
steering column coupler and dash
seal.
2. Noisy valve in power steering
gear.
2. Replace steering gear assembly.
3. Mis-routed power steering hose 3. Check for proper routing of power
steering hoses and ensure they do
contact other components.
Rattle Or Clunk 1. Steering gear loose on front
suspension crossmember.
1. Check steering gear to front
suspension crossmember mounting
bolts. Tighten to specified torque if
found to be loose.
2. Front suspension crossmember to
frame bolts or studs loose.
2. Tighten the front suspension
crossmember attaching bolts or
studs to the specified torque.
3. Tie rod is loose (outer or inner). 3. Check tie rod pivot points for
wear. Replace worn/loose parts as
required.
4. Loose lower control arm to front
suspension crossmember bolts.
4. Tighten control arm mounting
bolts to the specified torques.
5. Loose upper control arm/ shock
absorber mounting bracket to body
attaching bolts.
5. Check mounting bracket to body
attaching bolts for looseness. If
required tighten to the specified
torques.
6. Power steering fluid pressure
hose touching the body of the
vehicle.
6. Adjust hose to proper position by
loosening, repositioning, and
tightening fitting to specified torque.
Do not bend tubing.
7. Noise internal to power steering
gear.
8. Damaged front suspension
crossmember.
8. Replace front suspension
crossmember.
9. Loose stabilizer bar attaching link
mounting nuts.
9. Tighten the stabilizer bar attaching
link mounting nuts to the specified
torque.
Chirp or squeal (in the area of the
power steering pump). Particularly
noticeable at full wheel travel and
during standstill parking.
belt.
1. Adjust power steering pump drive
belt to specified tension.
19 - 2 STEERING NS
Power steering pump growl results from the development of high pressure fluid flow. Normally this noise
should not be high enough to be objectionable. Abnormal situations, such as a low oil level causing
aeration or hose touching the vehicle body, can create a noise level that could bring complaints.
WHINE OR GROWL (PUMP
NOISE)
1. Low fluid level. 1. Fill power steering fluid
reservoir to proper level and
perform leakage diagnosis.
(Recheck fluid level after power
steering fluid is free of air.)
2. Power steering hose touching
vehicle body or frame.
2. Reposition power steering
hose. Replace hose if tube ends
are bent.
3. Extreme wear of power
steering pump internal parts.
3. Replace power steering pump
and flush system.
SUCKING AIR SOUND 1. Loose clamp on power steering
fluid low pressure hose.
1. Tighten or replace hose clamp.
2. Missing O-Ring on power
steering pressure hose
connection.
2. Inspect connection and replace
O-Ring as required.
3. Low power steering fluid level 3. Fill power steering fluid
reservoir to proper level and
perform leakage diagnosis.
4. Air leak between power
steering fluid reservoir and power
steering pump.
4. Inspect and/or replace power
steering fluid reservoir or supply
hose as required.
SQUEAK OR RUBBING
SOUND
1. Sound coming from steering
column.
1.Check for squeak in steering
column. Inspect for contact
between shroud, intermediate
shaft, column, and steering wheel.
Realign if necessary. Note: Check
steering column for noise
without clockspriing installed
and with the steering column
shaft removed from the steering
intermediate shaft. This must be
done before removing the
steering column for a noise
complaint.
2. Check for lack or grease on
steering column dash panel to
lower coupler seal.
2.Clockspring 3. Replace Clockspring
3. Sound internal to steering gear. 4. Replace steering gear
assembly.
SCRUBBING OR KNOCKING
SOUND
1. Incorrect tire size. 1. Verify that tire size on vehicle is
the same as originally supplied.
2. Check clearance between tires
and other vehicle components,
through the full travel of the
suspension.
2. Correct as necessary.
3. Check for interference between
steering gear and other
components.
3.Correct as necessary.
4.Incorrect steering gear supplied. 4. Replace steering gear with
correct steering gear for specific
vehicle.
NS STEERING 19 - 3
BINDING STICKING SEIZED
SHAKE SHUDDER VIBRATION
CATCHES, STICKS IN CERTAIN
POSITIONS OR IS DIFFICULT TO
TURN.
1. Low power steering fluid level. 1. Fill power steering fluid reservoir
to specified level and perform
leakage diagnosis.
2. Tires not inflated to specified
pressure.
2. Inflate tires to the specified
pressure.
3. Lack of lubrication in front
suspension lower control arm ball
joints.
3. Replace lower ball joint.
4. Worn lower ball joint. 4. Replace the lower ball joint.
5. Lack of lubrication in steering
gear outer tie rod ends.
5. Replace tie rod end.
belt.
6. Tighten the power steering pump
drive belt to the specified tension.
See accessory drive in service
manual.
7. Faulty power steering pump flow
control. (Verify cause using Power
Steering Pump Test Procedure.)
7. Replace power steering pump.
8. Excessive friction in steering
column or intermediate shaft.
8. Correct condition. (See Steering
Column Service Procedure)
9. Steering column coupler binding. 9. Realign the steering column to
eliminate the binding condition.
10. Binding lower ball joint. 10. Replace the lower ball joint.
gear.
VIBRATION OF THE STEERING
WHEEL AND/OR DASH DURING
DRY PARK OR LOW SPEED
STEERING MANEUVERS.
1. Air in the fluid of the power
steering system.
1. Steering shudder can be expected
in new vehicles and vehicles with
recent steering system repairs.
Shudder should improve after the
vehicle has been driven several
weeks.
2. Tires not properly inflated. 2. Inflate tires to the specified
pressure.
3. Excessive engine vibration. 3. Ensure that the engine is running
properly.
4. Loose tie rod end. 4. Check the inner to outer tie rod
jam nut for looseness. If loose
tighten to the specified torque.
Inspect inner tie rod for looseness at
steering gear. Inspect outer tie rod
ball for excessive wear/looseness. If
inner tie rod is loose replace steering
gear, if outer tie has excessive wear
replace tie rod end.
5.Overcharged air conditioning
system.
5.Check air conditioning pump head
pressure. (See Air Conditioning
Refrigerant System Diagnosis)
19 - 4 STEERING NS
LOW ASSIST, NO ASSIST, HARD STEERING
POOR RETURN TO CENTER
STIFF, HARD TO TURN, SURGES,
MOMENTARY INCREASE IN
EFFORT WHEN TURNING.
1. Tires not properly inflated. 1. Inflate tires to specified pressure.
2. Low power steering fluid level. 2. Add power steering fluid as
required to power steering fluid
reservoir to obtain proper level.
Perform leakage diagnosis on power
steering system.
belt.
3. Tighten the power steering pump
drive belt to the specified tension. If
drive belt is defective, replace and
correctly tension.
4. Lack of lubrication in lower control
arm ball joint.
4. Replace lower ball joint.
5. Worn lower ball joint. 5. Replace lower ball joint.
6. Low power steering pump
pressure. (Verify using Power
Steering System Test Procedure)
6. Verify cause using the Power
Steering System Test Procedure.
Replace the power steering pump if
necessary.
7. High internal leak in steering gear
assembly.
7. Check steering system using the
Power Steering System Test
Procedure. If steering gear is
defective replace steering gear.
STEERING WHEEL DOES NOT
RETURN TO CENTER POSITION.
1. Tires not
inflated to specified pressure.
1. Inflate tires to specified pressure.
2. Improper front wheel alignment. 2. Check and adjust as necessary.
3. Steering column U-joints
misaligned.
3. Realign steering column U-joints.
4. Mispositioned dash cover. 4. Reposition dash cover.
To evaluate items 6 and 7, disconnect
the intermediate shaft. Turn the
steering wheel and feel or listen for
internal rubbing in steering column.
5. Steering wheel rubbing. 5. Adjust steering column shrouds to
eliminate rubbing condition.
6. Damaged, mis-positioned or
un-lubricated steering column coupler
to dash seal.
6. Determine condition which exists
and correct.
7. Binding shaft bearing
in steering column assembly.
7. Replace the steering column. Note:
Before replacing steering column,
disconnect intermediate steering
coupler from steering column shaft
and remove steering wheel,
clockspring and shrouds from
steering column. This must be done
to verify a binding shaft bearing in
the steering column before
replacing the steering column.
column coupler.
8. Replace steering column coupler.
9. Excessive friction in steering gear. 9. Replace steering gear.
10. Excessive friction in front strut
mount bearing
10. Replace the strut mount or strut
mount pivot bearing.
NS STEERING 19 - 5
LOOSE STEERING
EXCESSIVE STEERING WHEEL
KICKBACK OR TOO MUCH
STEERING WHEEL FREE PLAY.
1. Air in the fluid of the power
steering system.
1. Fill power steering fluid reservoir
to the specified level. Perform
procedure to bleed the air out of the
power steering system. Perform
leakage diagnosis.
2. Steering gear loose on front
suspension crossmember.
2. Check steering gear to front
suspension crossmember mounting
bolt torque. Tighten to specified
torque if found to be loose.
3. Worn, broken or loose steering
column to steering gear coupler.
3. Check for worn universal joint,
broken isolator or loose fasteners.
4. Free play in steering column. 4.Check components of steering
system and repair or replace as
required. Note: Inspect steering
column with steering wheel installed
and steering column shaft
disconnected from intermediate
coupler. Verify that steering wheel
attaching nut is tightened to the
specified torque. Verify that the 4
mounting nuts for the steering
column are tightened to the specified
torque.
5. Loose lower control arm ball joint. 5. Check and or replace the ball joint
or control arm as required.
6. Loose steering knuckle to lower
ball joint stud attaching nut.
6. Check attaching nut and tighten if
required to specified torque.
7. Front wheel bearings loose or
worn.
7. Tighten hub nut to specified
torque or replace with new parts as
necessary.
8. Loose outer tie rod ends. 8. Check free play of outer tie rod
ends and replace if required.
9. Loose inner tie rod ends. 9. Replace steering gear assembly.
10. Defective steering gear rotary
valve.
11. Intermediate steering shaft
coupler flex joint binding.
11. Replace intermediate steering
shaft/coupler.
19 - 6 STEERING NS
VEHICLE LEADS TO THE SIDE
POWER STEERING FLUID LEAK
STEERING WHEEL DOES NOT
WANT RETURN TO CENTER
POSITION.
1. Radial tire lead. 1.Rotate tires as recommended in
the Tire And Wheel Group of this
service manual.
2. Front suspension misaligned. 2. Align the front suspension as
required. Refer to the Wheel
Alignment Procedure in the
Suspension Group of this service
manual for the required wheel
alignment procedure.
3. Wheel braking. 3. Check for dragging brakes. Refer
to the procedures in the Brake
Group of this service manual.
4. Unbalanced steering gear valve.
(If this is the cause, the steering
efforts will be very light in direction
of lead and heavier in the opposite
direction.
4. Replace steering gear.
STEERING WHEEL HAS FORE
AND AFT LOOSENESS.
1. Steering wheel to steering column
shaft retaining nut not properly
tightened and torqued.
1. Tighten the retaining nut to its
specified torque specification.
2. Steering column lower bearing
spring retainer slipped on steering
column shaft.
2. Replace steering column.
3. Loose steering column to
instrument panel mounting nuts.
3. Verify that the 4 mounting nuts for
the steering column are tightened to
the specified torque.
4. Binding intermediate steering
shaft coupler.
4. Disconnect intermediate steering
coupler and see if looseness no
longer exists. If yes replace
intermendiate steering coupler.
LOW FLUID LEVEL WITH: NO
VISIBLE SIGNS OF A LEAK ON
THE STEERING GEAR, POWER
STEERING PUMP, FLOOR OR
ANYWHERE ELSE.
1. Overfilled power steering pump
fluid reservoir.
1. Adjust the power steering fluid fill
to the correct level.
LOW FLUID LEVEL WITH:
VISIBLE LEAK ON STEERING
GEAR, POWER STEERING
PUMP, FLOOR OR ANYWHERE
ELSE.
2. Power steering hose connections
at the power steering pump or
steering gear.
2. Check for loose fittings and if
found, tighten the fitting to its
specified torque. If fittings are tight
examine the fittings for damaged or
missing O-ring seals and replace as
required.
3. Power steering pump or power
steering gear leaking.
3. Identify the location of the leak
and repair or replace the component
as required. Refer to Power Steering
Pump and/or Power Steering Gear in
this group of the service manual for
required procedures.
NS STEERING 19 - 7
FOAMY OR MILKY POWER STEERING FLUID
AERATION AND OVERFLOW OF
FLUID.
1. Air leaks. 1. Check for air leaking into the
power steering system as described
under Sucking Air Diagnosis and
correct condition.
2. Low fluid level. 2. Extremely cold temperatures may
cause power steering fluid aeration if
the power steering fluid is low. Add
power steering fluid as required to
bring level up to specification.
3. Cracked power steering pump
housing.
3. Remove power steering pump
from vehicle and inspect the power
steering pump housing for cracks. If
a defect in the housing is found,
replace the power steering pump.
4. Water contamination. 4. Drain the power steering fluid
from the system if there is evidence
of contamination. Then refill the
system with fresh clean power
steering fluid.
19 - 8 STEERING NS
POWER STEERING PUMP
INDEX
page page
POWER STEERING PUMP OPERATION . . . . . . . 9
POWER STEERING PUMP FLOW RATE AND
PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . 9
SERVICE PROCEDURES
POWER STEERING PUMP INITIAL
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 10
POWER STEERING SYSTEM FLUID LEVEL
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.4 LITER POWER STEERING PUMP . . . . . . . . . 11
3.0 LITER POWER STEERING PUMP . . . . . . . . 13
3.3/3.8 LITER POWER STEERING PUMP . . . . . . 16
POWER STEERING FLUID PRESSURE HOSE . . 19
POWER STEERING FLUID RESERVOIR TO
PUMP SUPPLY HOSE . . . . . . . . . . . . . . . . . . . 18
POWER STEERING FLUID RETURN HOSE . . . . 21
REMOTE POWER STEERING FLUID
RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . . . . 22
POWER STEERING PUMP FLOW CONTROL
VALVE SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . 23
POWER STEERING PUMP PULLEY . . . . . . . . . . 23
SPECIFICATIONS
POWER STEERING PUMP FASTENER
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . 24
POWER STEERING SYSTEM
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . 24
SPECIAL TOOLS
POWER STEERING PUMP . . . . . . . . . . . . . . . . . 25
POWER STEERING PUMP OPERATION
Hydraul i c pressure for the operati on of the power
steeri ng gear i s provi ded by a bel t dri ven power
steeri ng pump (Fi g. 1). The power steeri ng pump i s a
constant fl ow rate and di spl acement vane type pump.
The power steeri ng pump used on al l appl i cati ons i s
the Vane-Submerged remote reservoi r styl e power
steeri ng pump.
The remote reservoi r type pump (Fi g. 1) has the
pump housi ng and i nternal components combi ned
wi th the fl ui d housi ng. But i t has a remote reservoi r
for the power steeri ng fl ui d suppl y.
POWER STEERING PUMP FLOW RATE AND
PRESSURE TEST
The fol l owi ng procedure can be used to test the
operati on of the power steeri ng system on the vehi -
cl e. Thi s test wi l l provi de the fl ow rate of the power
steeri ng pump al ong wi th the maxi mum rel i ef pres-
sure. Thi s test i s to be performed any ti me a power
steeri ng system probl em i s present to determi ne i f
the power steeri ng pump or power steeri ng gear i s
not functi oni ng properl y. The fol l owi ng pressure and
fl ow test i s performed usi ng Pressure/Fl ow Tester,
Speci al Tool 6815 (Fi g. 2).
Fig. 1 Vane Submerged Remote Reservoir Power
Fig. 2 Power Steering Pump Flow/Pressure Tester
NS STEERING 19 - 9
POWER STEERING PUMP FLOW AND
PRESSURE TEST PROCEDURE
(1) Check power steeri ng pump dri ve bel t tensi on
and adjust as necessary.
(2) Di sconnect power steeri ng fl ui d pressure hose,
at power steeri ng pump. Use a contai ner for dri ppi ng
fl ui d.
(3) Connect Pressure Gauge, Speci al Tool from ki t
6815 to both hoses usi ng adapter fi tti ngs. Connect
spare pressure hose, to power steeri ng pump pres-
sure hose fi tti ng.
(4) Compl etel y open val ve on Speci al Tool 6815.
(5) Start engi ne and l et i dl e l ong enough to ci rcu-
l ate power steeri ng fl ui d through fl ow/pressure test
and get ai r out of fl ui d. Then shut off engi ne.
(6) Check power steeri ng fl ui d l evel , and add fl ui d
as necessary. Start engi ne agai n and l et i dl e.
(7) Pressure gauge shoul d read bel ow 862 kPa
(125 psi ), i f above, i nspect the hoses for restri cti ons
and repai r as necessary. The i ni ti al pressure readi ng
shoul d be i n the range of 345-552 kPa (50-80 psi ).
The fl ow meter shoul d read between 1.3 and 1.9
GPM
CAUTION: The following test procedure involves
testing power steering pump maximum pressure
output and flow control valve operation. Do not
leave valve closed for more than 5 seconds as the
pump could be damaged.
(8) Cl ose val ve ful l y three ti mes and record hi gh-
est pressure i ndi cated each ti me. All three read-
ings must be within specifications and within
345 kPa (50 psi) of each other.
NOTE: Power steering pump maximum relief pres-
sure is 9653 to 10342 kPa (1400 to 1500 psi.).
I f power steeri ng pump pressures are wi thi n the
speci fi cati ons but not wi thi n 345 kPa (50 psi ) of each
other, then repl ace power steeri ng pump.
I f pressures are wi thi n 345 kPa (50 psi ) of each
other but bel ow speci fi cati ons, then repl ace power
steeri ng pump.
CAUTION: Do not force the pump to operate
against the stops for more than 5 seconds at a time
because, pump damage will result.
(9) Open test val ve. Turn steeri ng wheel to the
extreme l eft and ri ght posi ti ons unti l agai nst the
stops, recordi ng the hi ghest i ndi cated pressure at
each posi ti on. Compare pressure gauge readi ngs to
power steeri ng pump speci fi cati ons. I f hi ghest output
pressures are not the same agai nst ei ther stop, the
steeri ng gear i s l eaki ng i nternal l y and must be
repl aced.
SERVICE PROCEDURES
POWER STEERING SYSTEM FLUID LEVEL CHECK
WARNING: FLUID LEVEL SHOULD BE CHECKED
WITH ENGINE OFF TO PREVENT INJURY FROM
MOVING PARTS. DO NOT USE AUTOMATIC TRANS-
MISSION FLUID IN THE POWER STEERING SYS-
TEM. DO NOT OVERFILL THE POWER STEERING
SYSTEM.
Wi pe reservoi r fi l l er cap free of di rt. Then check
fl ui d l evel . The di psti ck shoul d i ndi cate COLD when
fl ui d i s at normal ambi ent temperature, approxi -
matel y 21C to 27C (70F to 80F). I n al l pumps add
fl ui d as necessary, use onl y Mopar Power Steering
Fluid, or equivalent. DO NOT USE ANY TYPE
OF AUTOMATIC TRANSMISSION FLUID.
POWER STEERING PUMP INITIAL OPERATION
CAUTION: The fluid level should be checked with
engine off to prevent injury from moving compo-
nents. Use only Mopar Power Steering Fluid. Do
not use automatic transmission fluid. Do not over-
fill.
Wi pe fi l l er cap cl ean, then check the fl ui d l evel .
The di psti ck shoul d i ndi cate FULL COLD when the
fl ui d i s at normal temperature of approxi matel y 21C
to 27C (70F to 80F).
(1) Fi l l the pump fl ui d reservoi r to the proper l evel
and l et the fl ui d settl e for at l east two (2) mi nutes.
(2) Start the engi ne and l et run for a few seconds.
Then turn the engi ne off.
(3) Add fl ui d i f necessary. Repeat the above proce-
dure unti l the fl ui d l evel remai ns constant after run-
ni ng the engi ne.
(4) Rai se the front wheel s off the ground.
(5) Start the engi ne. Sl owl y turn the steeri ng
wheel ri ght and l eft, l i ghtl y contacti ng the wheel
stops.
(6) Add power steeri ng fl ui d i f necessary.
(7) Lower the vehi cl e and turn the steeri ng wheel
sl owl y from l ock to l ock.
(8) Stop the engi ne. Check the fl ui d l evel and refi l l
as requi red.
(9) I f the fl ui d i s extremel y foamy, al l ow the vehi -
cl e to stand a few mi nutes and repeat the above pro-
cedure.
19 - 10 STEERING NS
2. 4 LITER POWER STEERING PUMP
REMOVE
WARNING: POWER STEERING OIL, ENGINE COM-
PONENTS AND THE EXHAUST SYSTEM MAY BE
EXTREMELY HOT IF ENGINE HAS BEEN RUNNING.
DO NOT START ENGINE WITH ANY LOOSE OR DIS-
CONNECTED HOSES. DO NOT ALLOW HOSES TO
TOUCH HOT EXHAUST MANIFOLD OR CATALYST.
(1) Remove cap from power steeri ng fl ui d reser-
voi r.
(2) Usi ng a si phon pump, remove as much power
steeri ng fl ui d as possi bl e from the power steeri ng
fl ui d reservoi r.
(3) Remove the (-) negati ve battery cabl e from the
battery and i sol ate cabl e.
(4) Remove the dri ve bel t from the power steeri ng
pump pul l ey. See Cool i ng, Group 7 for detai l ed
removal procedure.
(5) Loosen but do not remove the nut attachi ng
the front bracket for the power steeri ng pump (Fi g.
3) to the al umi num mounti ng bracket.
frame contact type hoi st. See Hoi sti ng, i n the Lubri -
ual for the requi red l i fti ng procedure.
(7) Di sconnect the oxygen sensor wi ri ng harness
from the vehi cl e wi ri ng harness. Access to connecti on
at vehi cl e wi ri ng harness i s through the oxygen sen-
sor wi ri ng harness grommet i n the fl oor pan of the
vehi cl e.
NOTE: The exhaust system needs to be removed
from the engine to allow for an area to remove the
power steering pump from the vehicle.
(8) Remove the catal yti c converter from the
exhaust mani fol d. Then remove al l the exhaust sys-
tem hangers/i sol ators from the brackets on the
exhaust system.
(9) Move the exhaust system as far rearward and
to the l eft si de of the vehi cl e as possi bl e (Fi g. 4).
(10) Rai se the heat sl eeve on the power steeri ng
return hose to expose the hose to steel tube connec-
ti on (Fi g. 5). Remove the hose from the power steer-
i ng fl ui d return l i ne on the front suspensi on cradl e
(Fi g. 5). Al l ow the remai ni ng power steeri ng fl ui d to
drai n from the power steeri ng pump and reservoi r
through the removed return hose.
Fig. 3 Power Steering Pump Bracket Attaching Nut
Fig. 4 Exhaust Positioned For Removing Power
Steering Pump
Fig. 5 Power Steering Return Hose At Return Line
NS STEERING 19 - 11
(11) Remove the accessory dri ve spl ash shi el d (Fi g.
6).
(12) Remove the power steeri ng fl ui d suppl y hose
comi ng from the remote fl ui d reservoi r, from the fi t-
ti ng on the power steeri ng pump (Fi g. 7). Drai n off
excess power steeri ng fl ui d from hose.
(13) Remove the power steeri ng fl ui d pressure l i ne
(Fi g. 8) from the power steeri ng pump. Drai n excess
power steeri ng fl ui d from tube.
(14) Remove the power steeri ng fl ui d return hose
(15) Remove the nut attachi ng rear of power steer-
i ng pump to the cast mounti ng bracket. (Fi g. 9)
(16) Loosen the 3 bol ts (Fi g. 10) attachi ng the
power steeri ng pump to i ts front mounti ng bracket.
Then remove the nut and the bol t (Fi g. 10), attachi ng
the power steeri ng pump front to the cast bracket.
(17) Remove the power steeri ng pump and the
front bracket from the cast bracket as an assembl y.
Fig. 6 Accessory Drive Splash Shield
Fig. 7 Power Steering Hoses At Power Steering
Pump
Fig. 8 Power Steering Fluid Pressure And Return
Hose
Fig. 9 Power Steering Pump Attaching Nut
Fig. 10 Power Steering Pump Mounting To Front
Bracket
19 - 12 STEERING NS
(18) Remove the 3 previ ousl y l oosened bol ts
attachi ng the front bracket to the power steeri ng
pump and separate the power steeri ng pump from
the front bracket pri or to removi ng the pump from
the vehi cl e.
(19) The power steeri ng pump i s removed from the
vehi cl e by pul l i ng i t out through the exhaust tunnel
area i n the fl oor pan of the vehi cl e.
INSTALL
(1) I nstal l power steeri ng pump back i n vehi cl e
usi ng the reverse order of i ts removal through the
exhaust tunnel are of the vehi cl e.
(2) I nstal l the power steeri ng pump on i ts cast
mounti ng bracket and l oosel y i nstal l nut to hol d
pump i n pl ace (Fi g. 9).
(3) I nstal l the front bracket on the power steeri ng
pump and l oosel y i nstal l the 3 mounti ng bol ts (Fi g.
10). Then i nstal l the nut and bol t attachi ng the front
bracket to the cast bracket (Fi g. 10).
(4) Ti ghten the 3 power steeri ng pump mounti ng
bol ts (Fi g. 10) to a torque of 54 Nm (40 ft. l bs.).
NOTE: Before installing power steering fluid pres-
sure hose on power steering pump, inspect the
O-ring on the pressure hose for damage and
replace if necessary.
(5) I nstal l the power steeri ng fl ui d pressure l i ne
onto the output fi tti ng of the power steeri ng pump
(Fi g. 8). Ti ghten the pressure l i ne to pump fi tti ng
tube nut to a torque of 31 Nm (275 i n. l bs.).
(6) I nstal l the power steeri ng fl ui d, l ow pressure
return hose on the power steeri ng pump l ow pressure
fi tti ng (Fi g. 8). Be sure hose clamps are properly
reinstalled.
(7) I nstal l the power steeri ng fl ui d suppl y hose
from the power steeri ng fl ui d reservoi r, on the power
steeri ng pump fl ui d fi tti ng (Fi g. 7). Be sure hose is
clear of accessory drive belts all hose clamps
are properly reinstalled.
(8) I nstal l the power steeri ng pump dri ve bel t on
pul l ey. See Cool i ng, Group 7 for detai l ed i nstal l ati on
procedure.
(9) I nstal l the accessory dri ve spl ash shi el d (Fi g.
6).
(10) I nstal l the power steeri ng fl ui d return hose on
the steel tube at the front suspensi on cradl e (Fi g. 5).
(11) I nstal l a screw type hose cl amp on the power
steeri ng hose to steel tube connecti on. Be sure hose
clamps are properly reinstalled.Ti ghten the screw
cl amp to a torque of 2 Nm (18 i n. l bs.).
CAUTION: The protective heat shield sleeves must
cover the entire rubber hose and hose to tube con-
nection portion of both the power steering fluid
pressure and return hoses (Fig. 5). This is required
to prevent the overheating of the power steering
hoses.
(12) When used, properl y posi ti on the protecti ve
heat sl eeves on the power steeri ng hoses (Fi g. 5).
Then, ti e strap the heat sl eeves to the power steeri ng
hoses to keep them i n thei r proper posi ti on.
(13) I nstal l the exhaust pi pe on the exhaust man-
i fol d. I nstal l al l exhaust system hangers/i sol ators on
the exhaust system brackets.
(14) Connect the oxygen sensor wi ri ng harness to
the vehi cl e wi ri ng harness. I nstal l wi ri ng harness
grommet i n the fl oor pan of the vehi cl e.
(16) Adjust the power steeri ng pump dri ve bel t.
See Cool i ng, Group 7 for detai l ed adjustment proce-
dure.
(17) Ti ghten the top nut and bottom bol t on the
power steeri ng pump front mounti ng bracket (Fi g. 3)
CAUTION: Do not use automatic transmission fluid
in power steering system. Only use Mopar, Power
Steering Fluid, or equivalent.
(18) Fi l l the remote power steeri ng pump fl ui d res-
ervoi r to correct fl ui d l evel .
(19) I nstal l cap on power steeri ng fl ui d reservoi r.
(20) Connect the negati ve battery cabl e on the
negati ve battery post.
(21) Start engi ne and turn steeri ng wheel several
ti mes from stop to stop to bl eed ai r from fl ui d i n sys-
tem. Stop engi ne, check fl ui d l evel , and i nspect sys-
tem for l eaks. See Checki ng Fl ui d Level .
3. 0 LITER POWER STEERING PUMP
REMOVE
voi r.
fl ui d reservoi r.
NS STEERING 19 - 13
(4) Remove the serpenti ne accessory dri ve bel t
from the engi ne (Fi g. 11). See Cool i ng, Group 7 for
detai l ed removal procedure.
vehi cl e.
exhaust system.
return hose to expose the return hose to steel tube
connecti on. Remove the hose from the power steeri ng
fl ui d return l i ne on the front suspensi on cradl e (Fi g.
13). Al l ow the remai ni ng power steeri ng fl ui d to
drai n from the power steeri ng pump and reservoi r
through the removed hose.
(10) Remove the accessory dri ve spl ash shi el d
(Fi g. 14).
NOTE: If the return hose is not removed from the
power steering pump, it is very difficult to remove
the power steering pump from the vehicle.
Fig. 11 3.0L Serpentine Drive Belt And Routing
Fig. 12 Exhaust Position For Removing Power
Steering Pump
19 - 14 STEERING NS
(Fi g. 15) from the power steeri ng pump.
(14) Remove the support bracket at the rear of the
power steeri ng pump attachi ng the pump to the rear
of the engi ne (Fi g. 16).
(15) Remove the 2 bol ts mounti ng the power steer-
i ng pump to the al ternator/power steeri ng pump and
bel t tensi oner mounti ng bracket (Fi g. 16).
(16) Remove the power steeri ng pump from i ts
mounti ng bracket.
INSTALL
(2) I nstal l the power steeri ng pump on i ts mount-
i ng bracket. I nstal l the 2 power steeri ng pump
mounti ng bol ts (Fi g. 16). Ti ghten the power steeri ng
pump mounti ng bol ts to a torque of 54 Nm (40 ft.
l bs.).
(3) I nstal l the support bracket attachi ng rear of
power steeri ng pump to engi ne (Fi g. 16). Ti ghten the
nut and bol ts to a torque of 54 Nm (40 ft. l bs).
NOTE: Before connecting the power steering pres-
sure line to the power steering pump, inspect the
O-ring on the pressure line for damage and replace
if damaged.
(5) I nstal l the power steeri ng fl ui d l ow pressure
fi tti ng (Fi g. 15). Be sure hose clamps are prop-
erly reinstalled and return hose is clear of all
accessory drive belts.
steeri ng pump fl ui d fi tti ng (Fi g. 15). Be sure all
hose clamps are properly reinstalled.
(7) I nstal l the serpenti ne dri ve bel t (Fi g. 11). See
Cool i ng, Group 7 for detai l ed i nstal l ati on procedure.
the steel tube at the front suspensi on cradl e (Fi g.
13).
steeri ng hose to steel tube connecti on. Ti ghten the
screw cl amp to a torque of 2 Nm (18 i n. l bs.).
to prevent overheating of the power steering hoses.
heat sl eeves on the power steeri ng hoses. Then, ti e
strap the heat sl eeves to the power steeri ng hoses to
keep them i n thei r proper posi ti on.
14).
Pump
Fig. 16 Power Steering Pump Mounting
NS STEERING 19 - 15
3. 3/3. 8 LITER POWER STEERING PUMP
REMOVE
voi r.
fl ui d reservoi r.
vehi cl e.
exhaust system.
hoses to expose the hose to steel tube connecti on.
Remove the hose from the power steeri ng fl ui d
return l i ne on the front suspensi on cradl e (Fi g. 18).
Al l ow the remai ni ng power steeri ng fl ui d to drai n
from the pump and fl ui d reservoi r through the
removed return hose.
(9) Remove the accessory dri ve spl ash shi el d (Fi g.
19).
Fig. 17 Exhaust Position For Removing Power
Steering Pump
19 - 16 STEERING NS
(10) Remove the serpenti ne accessory dri ve bel t
from the engi ne (Fi g. 20). See Cool i ng, Group 7 for
detai l ed removal procedure.
(14) Remove the support bracket at the rear of the
power steeri ng pump attachi ng the pump to the rear
of the engi ne (Fi g. 22).
(15) Remove the 3 bol ts mounti ng the power steer-
i ng pump to the al ternator/power steeri ng pump and
bel t tensi oner mounti ng bracket (Fi g. 23).
(16) Remove the power steeri ng pump from i ts
mounti ng bracket.
INSTALL
(2) I nstal l the power steeri ng pump on i ts mount-
i ng bracket. I nstal l the 3 power steeri ng pump
mounti ng bol ts (Fi g. 23). Ti ghten the power steeri ng
pump mounti ng bol ts to a torque of 54 Nm (40 ft.
l bs.).
(3) I nstal l the support bracket attachi ng rear of
power steeri ng pump to engi ne (Fi g. 22). Ti ghten the
nut and bol t hol di ng the strut assembl y to bracket
and the i ntake mani fol d stud to a torque of 54 Nm
(40 ft. l bs).
Fig. 20 Serpentine Drive Belt And Routing
Pump
Fig. 22 Power Steering Pump Support Bracket
Fig. 23 Power Steering Pump Mounting Bolts
NS STEERING 19 - 17
NOTE: Before installing power steering pressure
hose on power steering pump, inspect the O-ring
on the power steering pressure hose for damage
and replace if required.
(5) I nstal l the power steeri ng fl ui d, l ow pressure
fi tti ng (Fi g. 21). Be sure hose clamps are prop-
erly reinstalled.
steeri ng pump fl ui d fi tti ng (Fi g. 21). Be sure hose is
clear of accessory drive belts and all hose
clamps are properly reinstalled.
(7) I nstal l the serpenti ne dri ve bel t (Fi g. 20). See
Cool i ng, Group 7 for detai l ed i nstal l ati on procedure.
18).
clamps are properly reinstalled.Ti ghten the screw
cl amp to a torque of 2 Nm (18 i n. l bs.).
to keep the power steering hoses from becoming
overheated.
heat sl eeves on the power steeri ng hoses (Fi g. 18).
19).
POWER STEERING FLUID RESERVOIR TO PUMP
SUPPLY HOSE
REMOVE
(1) Remove the fi l l er cap from remote power steer-
i ng fl ui d reservoi r (Fi g. 24).
fl ui d reservoi r.
(3) Remove power steeri ng fl ui d suppl y hose rout-
i ng cl i p (Fi g. 25) from stud i n strut tower.
Fig. 24 Fluid Supply Hose At Power Steering Fluid
Reservoir
Fig. 25 Power Steering Fluid Hose Routing Clip
19 - 18 STEERING NS
thi s vehi cl e.
(5) Remove at power steeri ng pump, the power
steeri ng fl ui d hose comi ng from the power steeri ng
fl ui d reservoi r. Let the power steeri ng fl ui d drai n out
of the reservoi r and hose.
(7) Remove hose cl amp attachi ng the power steer-
i ng fl ui d suppl y hose to the power steeri ng fl ui d res-
ervoi r (Fi g. 24).
from the vehi cl e. Hose i s removed from the top of the
engi ne compartment.
INSTALL
CAUTION: On V-6 engine applications, the power
steering fluid reservoir to power steering hose must
be routed tightly against the strut tower and parallel
to the dash panel. It must also be routed under the
wiring harness and below the drip tube. This rout-
ing will prevent the power steering fluid supply
hose from coming in contact with the accessory
drive belt.
(1) I nstal l and correctl y route the power steeri ng
fl ui d suppl y hose from remote fl ui d reservoi r down to
power steeri ng pump.
(2) I nstal l the fl ui d suppl y hose onto the power
steeri ng fl ui d reservoi r (Fi g. 24). I nstal l the hose
cl amp on the fl ui d suppl y hose. Be sure hose clamp
is installed past bead on fluid reservoir fitting.
thi s vehi cl e.
(4) I nstal l power steeri ng fl ui d suppl y hose on
power steeri ng pump. I nstal l the hose cl amp on the
fl ui d suppl y hose. Be sure hose clamp is installed
past bead on pump fitting.
(6) I nstal l routi ng cl i p on power steeri ng fl ui d sup-
pl y hose. Be sure routi ng cl i p i s i nstal l ed i n a posi -
ti on to correctl y al i gn wi th stud i n strut tower.
(7) I nstal l routi ng cl i p for power steeri ng fl ui d sup-
pl y hose on stud i n strut tower (Fi g. 25).
(8) Fi l l the remote fl ui d reservoi r to the proper
l evel and l et the fl ui d settl e for at l east two (2) mi n-
utes.
(10) Add fl ui d i f necessary. Repeat the above pro-
cedure unti l the fl ui d l evel remai ns constant after
runni ng the engi ne.
stops.
(15) Stop the engi ne. Check the fl ui d l evel and
refi l l as requi red.
cedure.
POWER STEERING FLUID PRESSURE HOSE
Servi ce al l power steeri ng hoses wi th vehi cl e rai sed
on hoi st. Cap al l open ends of hoses, power steeri ng
pump fi tti ngs and steeri ng gear ports to prevent
entry of forei gn materi al i nto the components.
WARNING: POWER STEERING OIL, ENGINE
PARTS AND THE EXHAUST SYSTEM MAY BE
For part reference and part l ocati on for the vehi cl e
that i s bei ng servi ced, refer to the fol l owi ng fi gure
numbers. These show the hose bracket l ocati ons,
hose routi ngs and fi tti ng l ocati ons by the engi ne
appl i cati on of the vehi cl e. Use these fi gure numbers
when referri ng to the removal or i nstal l ati on proce-
dures for the power steeri ng hoses l i sted bel ow.
REMOVE
voi r.
fl ui d reservoi r.
(3) Rai se vehi cl e See Hoi sti ng, Group 0. Put oi l
drai n pan under vehi cl e to catch power steeri ng fl ui d.
fl ui d return hose (Fi g. 26) to expose the return hose
to steel tube connecti on. Remove the hose cl amp from
the power steeri ng fl ui d return hose (Fi g. 26).
Remove power steeri ng fl ui d return hose from steel
tube and al l ow power steeri ng fl ui d to drai n from
pump.
NS STEERING 19 - 19
from the power steeri ng pump pressure fi tti ng (Fi g.
27). Drai n excess power steeri ng fl ui d from hose.
(6) Remove bol t, attachi ng power steeri ng hose
routi ng bracket to front suspensi on cradl e (Fi g. 28).
(7) Di sconnect power steeri ng hose at power steer-
i ng gear assembl y (Fi g. 29). Drai n the power steeri ng
fl ui d from power steeri ng pump and hose.
(8) Di scard the O-ri ngs on the ends of power steer-
i ng fl ui d pressure hose.
INSTALL
(1) Usi ng a l i nt free towel , wi pe cl ean the open
power steeri ng hose ends, power steeri ng pump pres-
sure fi tti ng and steeri ng gear ports.
(2) I nstal l new O-ri ngs on the ends of the power
steeri ng fl ui d pressure hose. Lubri cate O-ri ngs usi ng
cl ean power steeri ng fl ui d.
(3) Attach the power steeri ng pressure hose to the
fi tti ngs on the power steeri ng pump and steeri ng
gear. Route hose avoi di ng ti ght bends or ki nki ng. Do
not bend tube ends of the power steeri ng hoses when
i nstal l i ng.
(4) I nstal l the power steeri ng fl ui d hoses to sus-
pensi on cradl e routi ng bracket (Fi g. 28). Power steer-
i ng fl ui d hoses must remai n away from the exhaust
system and must not come i n contact wi th any
unfri endl y surfaces of the vehi cl e.
CAUTION: When tightening and torquing the pres-
sure hose at the power steering pump, the pressure
hose is to be rotated against the fluid return hose
fitting on the pump.
(5) Ti ghten al l fasteners shown for speci fi c appl i ca-
ti ons to thei r correct torques l i sted bel ow:
Pump End Tube Nut 34 Nm (25 ft. l bs.)
Gear End Tube Nut 34 Nm (25 ft. l bs.)
Pump Bracket Nut 40 Nm (30 ft. l bs.)
Fig. 26 Return Hose Connection To Steel Tube
Fig. 27 Pressure Hose Connection To Power
Steering Pump
Fig. 28 Power Steering Hose Attachment To
Suspension Cradle
Fig. 29 Power Steering Pressure Hose At Steering
Gear
19 - 20 STEERING NS
26).
CAUTION: The protective heat sleeves must cover
the entire rubber hose and hose to tube connection
portion of both the power steering fluid pressure
and return hoses (Fig. 26).
(9) After hoses are i nstal l ed and power steeri ng
system i s fi l l ed wi th fl ui d and cap i s i nstal l ed on res-
ervoi r. Start the engi ne and check for l eaks. (See
Pump I nstal l ati on).
POWER STEERING FLUID RETURN HOSE
Servi ce al l power steeri ng hoses wi th vehi cl e rai sed
on hoi st. Cap al l open ends of hoses, power steeri ng
pump fi tti ngs and steeri ng gear ports to prevent
entry of forei gn materi al i nto the components.
For part reference and part l ocati on for the vehi cl e
that i s bei ng servi ced, refer to the fol l owi ng fi gure
numbers. These show the hose bracket l ocati ons,
hose routi ngs and fi tti ng l ocati ons by the engi ne
appl i cati on of the vehi cl e. Use these fi gure numbers
when referri ng to the removal or i nstal l ati on proce-
dures for the power steeri ng hoses l i sted bel ow.
REMOVE
voi r.
fl ui d reservoi r.
(4) Rai se the i nsul ati ng heat sl eeve on the power
steeri ng hoses to expose the hose to steel tube con-
necti on. Remove hose cl amp where rubber porti on of
power steeri ng fl ui d return hose attaches to steel
tube on suspensi on cradl e (Fi g. 30). Remove rubber
hose from steel tube and al l ow power steeri ng fl ui d
to drai n from pump.
from the power steeri ng pump return hose fi tti ng.
INSTALL
(1) Usi ng a l i nt free towel , wi pe cl ean the open
power steeri ng hose ends and power steeri ng pump
fi tti ng.
(2) Attach the power steeri ng return hose to the
fi tti ng on the power steeri ng pump. Route hose
smoothl y avoi di ng ti ght bends or ki nki ng. Hose must
remai n away from the exhaust system and not come
i n contact wi th any unfri endl y surfaces of the vehi -
cl e.
30).
pressure and return hoses (Fig. 30). This is to pre-
vent overheating of the power steering fluid hoses.
(5) When used, posi ti on the protecti ve heat sl eeves
on the power steeri ng hoses so they cover the connec-
ti on to the power steeri ng pump. Then, ti e strap the
heat sl eeves to the power steeri ng hoses to keep
them i n thei r proper posi ti on.
(6) After hoses are i nstal l ed and power steeri ng
system i s fi l l ed wi th fl ui d and cap i s i nstal l ed on res-
ervoi r. Start the engi ne and check for l eaks. (See
Pump I nstal l ati on).
Fig. 30 Power Steering Return Hose At Steel Tube
NS STEERING 19 - 21
REMOTE POWER STEERING FLUID RESERVOIR
REMOVE
(1) Remove the fi l l er cap from remote power steer-
i ng fl ui d reservoi r (Fi g. 31).
thi s vehi cl e.
(3) Remove at power steeri ng pump, the power
steeri ng fl ui d hose comi ng from the power steeri ng
fl ui d reservoi r. Let the power steeri ng fl ui d drai n out
of the reservoi r and hose.
(5) Remove the fl ui d suppl y hose (Fi g. 31) from the
remote power steeri ng fl ui d reservoi r.
(6) Remove the 2 mounti ng screws (Fi g. 31)
attachi ng the remote fl ui d reservoi r to the i nner
fender.
(7) Remove remote reservoi r from i nner fender.
INSTALL
(1) I nstal l remote power steeri ng fl ui d reservoi r on
i nner fender, by fi rst i nserti ng tab on reservoi r i nto
hol e i n i nner fender. Then rotate reservoi r so mount-
i ng tabs are agai nst i nner fender.
(2) I nstal l and securel y ti ghten the 2 reservoi r
mounti ng screws (Fi g. 31).
CAUTION: The power steering fluid reservoir to
power steering pump supply hose must be routed
tightly against the strut tower and parallel to the
dash panel. It must also be routed under the wiring
harness and below the drip tube. This will prevent
the hose from coming in contact with the accessory
drive belt. The power steering fluid supply hose
must be located in its correct position by clipping it
to the stud in the strut tower (Fig. 32).
(3) I nstal l the fl ui d suppl y hose onto the power
steeri ng fl ui d reservoi r fi tti ng (Fi g. 31). I nstal l the
hose cl amp on the fl ui d suppl y hose at the fl ui d res-
ervoi r. Be sure hose clamp in installed past bead
on fluid reservoir fitting.
thi s vehi cl e.
(5) I nstal l power steeri ng fl ui d suppl y hose on
power steeri ng pump. I nstal l the hose cl amp on the
fl ui d suppl y hose at the power steeri ng pump. Be
sure hose clamp in installed past bead on pump
fitting.
(7) I nstal l routi ng cl i p for power steeri ng fl ui d sup-
pl y hose on stud i n strut tower (Fi g. 32).
(8) Fi l l the remote fl ui d reservoi r to the proper
l evel and l et the fl ui d settl e for at l east two (2) mi n-
utes.
stops.
cedure.
Fig. 31 Remote Power Steering Fluid Reservoir
Fig. 32 Power Steering Fluid Hose Routing Clip
19 - 22 STEERING NS
POWER STEERING PUMP PULLEY
DISASSEMBLY
(1) Remove the pul l ey from the shaft of the power
steeri ng pump usi ng Pul l er C-4333 or C-4068 (Fi g.
33).
CAUTION: Do not hammer on power steering
pump pulley. This will damage the pulley and the
power steering pump.
(2) Repl ace pul l ey i f i t i s found to be bent, cracked,
or l oose.
ASSEMBLY
(1) I nstal l the pul l ey wi th I nstal l er C-4063 (Fi g.
34). Do not use the tool adapters.
(2) Ensure that the tool and the pul l ey remai n
al i gned wi th the pump shaft. Prevent the pul l ey from
bei ng cocked on the shaft.
(3) Force pul l ey fl ush wi th the end of the power
steeri ng pump shaft (Fi g. 35).
(4) Wi th serpenti ne bel ts, run engi ne unti l warm
(5 mi n.) and note any bel t chi rp. I f chi rp exi sts, move
pul l ey outward approxi matel y 0.5 mm (0.020 i n.). I f
noi se i ncreases, press on 1.0 mm (0.040 i n.). Be
careful that pulley does not contact mounting
bolts.
POWER STEERING PUMP FLOW CONTROL VALVE
SEAL
DISASSEMBLE
voi r.
fl ui d reservoi r.
(4) Rai se the heat sl eeve (Fi g. 36) on the power
steeri ng return hose to expose the return hose to
steel tube connecti on. Remove hose cl amp from
power steeri ng fl ui d return hose (Fi g. 36). Remove
power steeri ng return hose from steel tube and al l ow
remai ni ng power steeri ng fl ui d to drai n from power
steeri ng pump and reservoi r.
from the power steeri ng pump pressure fi tti ng (Fi g.
37). Drai n excess power steeri ng fl ui d from hose.
Fig. 33 Pulley Removal
Fig. 34 Pulley Installation
Fig. 35 Pulley To Pump Shaft Location
NS STEERING 19 - 23
(6) Remove the pressure fi tti ng/fl ow control val ve
from the power steeri ng pump and remove and di s-
card the O-Ri ng seal .
ASSEMBLE
(1) I nstal l a new O-Ri ng seal on the pressure fi t-
ti ng/fl ow control val ve, and wet the O-Ri ng wi th
cl ean fresh power steeri ng fl ui d.
(2) I nstal l the pressure fi tti ng/fl ow control val ve i n
the power steeri ng pump. Ti ghten the pressure fi t-
ti ng/fl ow control val ve to a torque of 75 Nm (55 ft.
l bs.).
CAUTION: When tightening and torquing the pres-
sure hose at the power steering pump, the hose
should be rotated against the fluid return hose fit-
ting on the pump.
(3) I nstal l the power steeri ng fl ui d pressure hose
i n the pressure fi tti ng/fl ow control val ve (Fi g. 37).
Ti ghten the tube nut to a torque of 34 Nm (25 ft.
l bs.)
36).
to keep the power steering hoses from becoming
overheated.
heat sl eeves (Fi g. 36) on the power steeri ng hoses.
(7) Fi l l the power steeri ng system wi th fl ui d, bl eed
ai r from system and check that power steeri ng fl ui d
i s at correct l evel .
SPECIFICATIONS
POWER STEERING SYSTEM SPECIFICATIONS
Fl ow At 1500 RPM And Mi ni mum Pressure.5.0 to 7.0
Li ters/Mi n (1.3 to 1.9 GPM)
Control Val ve Pressure Rel i ef. 9653 to 10342 kPa (1400
to 1500psi )
POWER STEERING PUMP FASTENER TORQUE
SPECIFICATIONS
DESCRIPTION TORQUE
POWER STEERING PUMP:
Fl ow Control Val ve Fi tti ng . . . .75 Nm (55 ft. l bs.)
Rear Bracket To Engi ne
POWER STEERING FLUID HOSES:
Hose Tube Nuts . . . . . . . . . . . . .34 Nm (25 ft. l bs.)
Routi ng Bracket To
Suspensi on Cradl e . . . . . . . . . .28 Nm (21 ft. l bs.)
Fig. 36 Return Hose At Steel Tube
Fig. 37 Pressure Hose Connection To Power
Steering Pump
19 - 24 STEERING NS
SPECIAL TOOLS
POWER STEERING PUMP
Installer C-4063B
Puller C-4333
P/S System Analyzer 6815
NS STEERING 19 - 25
POWER STEERING GEAR
INDEX
page page
STEERING GEAR OPERATION DESCRIPTION . 26
POWER STEERING GEAR . . . . . . . . . . . . . . . . . 27
STEERING GEAR . . . . . . . . . . . . . . . . . . . . . . . 27
OUTER TIE ROD END . . . . . . . . . . . . . . . . . . . 33
STEERING GEAR INNER TIE ROD BOOT . . . . . 31
SPECIFICATIONS
STEERING GEAR FASTENER TORQUE
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . 34
SPECIAL TOOLS
POWER STEERING GEAR . . . . . . . . . . . . . . . . . 35
STEERING GEAR OPERATION DESCRIPTION
NOTE: The power steering gear (Fig. 1) should NOT
be serviced or adjusted. If a malfunction or oil leak
occurs, the complete steering gear should be
replaced.
I f a steeri ng gear boot needs to be repl aced due to
damage, refer to the power steeri ng gear servi ce sec-
ti on i n thi s manual for proper procedure.
The power steeri ng system consi sts of these four
major components. Power Steeri ng Gear, Power
Steeri ng Pump, Pressure Hose, and Return Li ne.
Turni ng of the steeri ng wheel i s converted i nto l i near
travel through the meshi ng of the hel i cal pi ni on
teeth wi th the rack teeth. Power assi st steeri ng i s
provi ded by an open center, rotary type control val ve
whi ch di rects oi l from the pump to ei ther si de of the
i ntegral rack pi ston.
Road feel i s control l ed by the di ameter of a torsi on
bar whi ch i ni ti al l y steers the vehi cl e. As requi red
steeri ng effort i ncreases, as i n a turn, the torsi on bar
twi sts, causi ng rel ati ve rotary moti on between the
rotary val ve body and the val ve spool . Thi s move-
ment di rects oi l behi nd the i ntegral rack pi ston,
whi ch, i n turn, bui l ds up hydraul i c pressure and
assi sts i n the turni ng effort.
Fig. 1 Power Steering Gear Assembly
19 - 26 STEERING NS
The dri ve tangs on the pi ni on mate l oosel y wi th a
stub shaft to permi t manual steeri ng control to be
mai ntai ned i f the dri ve bel t on the power steeri ng
pump shoul d break. However, under these condi ti ons,
steeri ng effort wi l l be i ncreased.
POWER STEERING GEAR
The fol l owi ng procedure can be used to test the
operati on of the power steeri ng system on thi s vehi -
cl e. Thi s test wi l l provi de the fl ow rate for the power
steeri ng system al ong wi th the maxi mum rel i ef pres-
sure of the power steeri ng pump. Thi s test i s to be
performed any ti me a power steeri ng system probl em
i s present to determi ne i f the power steeri ng pump or
power steeri ng gear i s not functi oni ng properl y. The
fol l owi ng pressure and fl ow test i s performed usi ng
Pressure/Fl ow Tester, Speci al Tool 6815 (Fi g. 2).
POWER STEERING PUMP FLOW AND
PRESSURE TEST PROCEDURE
(1) Check power steeri ng pump dri ve bel t tensi on
and adjust as necessary.
(2) Di sconnect power steeri ng fl ui d pressure hose,
at power steeri ng pump. Use a contai ner for dri ppi ng
fl ui d.
(3) Connect Pressure Gauge, Speci al Tool from ki t
6815 to both hoses usi ng adapter fi tti ngs. Connect
spare pressure hose, to power steeri ng pump pres-
sure hose fi tti ng.
(4) Compl etel y open val ve on Speci al Tool 6815.
(5) Start engi ne and l et i dl e l ong enough to ci rcu-
l ate power steeri ng fl ui d through fl ow/pressure test
and get ai r out of fl ui d. Then shut off engi ne.
(6) Check power steeri ng fl ui d l evel , and add fl ui d
as necessary. Start engi ne agai n and l et i dl e.
(7) Pressure gauge shoul d read bel ow 862 kPa
(125 psi ), i f above, i nspect the hoses for restri cti ons
and repai r as necessary. The i ni ti al pressure readi ng
shoul d be i n the range of 345-552 kPa (50-80 psi ).
The fl ow meter shoul d read between 1.3 and 1.9
GPM
CAUTION: The following test procedure involves
testing power steering pump maximum pressure
output and flow control valve operation. Do not
leave valve closed for more than 5 seconds as the
pump could be damaged.
(8) Cl ose val ve ful l y three ti mes and record hi gh-
est pressure i ndi cated each ti me. All three read-
ings must be within the specifications and
within 345 kPa (50 psi) of each other.
NOTE: Power steering pump maximum relief pres-
sure is 9653 to 10342 kPa (1400 to 1500 psi.).
I f power steeri ng pump pressures are wi thi n
speci fi cati ons but not wi thi n 345 kPa (50 psi ) of each
other, then repl ace power steeri ng pump.
I f pressures are wi thi n 345 kPa (50 psi ) of each
other but bel ow speci fi cati ons, then repl ace power
steeri ng pump.
CAUTION: Do not force the pump to operate
against the stops for more than 5 seconds at a time
because, pump damage will result.
(9) Open test val ve. Turn steeri ng wheel to the
extreme l eft and ri ght posi ti ons unti l agai nst the
stops, recordi ng the hi ghest i ndi cated pressure at
each posi ti on. Compare pressure gauge readi ngs to
power steeri ng pump speci fi cati ons. I f hi ghest output
pressures are not the same agai nst ei ther stop, the
steeri ng gear i s l eaki ng i nternal l y and must be
repl aced.
STEERING GEAR
NOTE: The power steering gear should NOT be ser-
viced or adjusted. If a malfunction or oil leak
occurs, the complete steering gear assembly must
be replaced.
REMOVE
CAUTION: Positioning the steering column in the
locked position will prevent the clockspring from
being accidentally over-extended when the steering
column is disconnected from the intermediate
steering coupler.
Fig. 2 Power Steering Pump Flow/Pressure Tester
NS STEERING 19 - 27
voi r.
fl ui d reservoi r.
(3) Wi th the i gni ti on key i n the l ocked posi ti on
turn the steeri ng wheel to the l eft unti l the steeri ng
wheel i s i n the l ocked posi ti on.
(4) Wi th the vehi cl e on the ground, di sconnect the
steeri ng col umn shaft coupl er from the steeri ng gear
i ntermedi ate coupl er (Fi g. 3).
thi s vehi cl e.
(6) Remove the front ti res.
(7) Rai se the heat sl eeve (Fi g. 4) on the power
steeri ng return hose to expose the return hose to
steel tube connecti on. Remove the return hose from
the metal tube of the power steeri ng fl ui d return l i ne
(Fi g. 4). Then al l ow the remai ni ng power steeri ng
fl ui d to drai n from the system through the hose and
metal tube.
loosening and removing nut with wrench.
(9) Remove both ti e rod ends from steeri ng knuck-
l es, usi ng Pul l er Speci al Tool MB-990635 or
MB-991113 (Fi g. 6).
Fig. 3 Steering Column Shaft To Intermediate Shaft
Attachment
Fig. 4 Power Steering Fluid Return Hose
Connection
Fig. 5 Removing/Installing Tie Rod End Attaching
Nut
Fig. 6 Tie Rod End Removal From Steering Knuckle
19 - 28 STEERING NS
(10) Remove the 2 bol ts and l oosen the thi rd (Fi g.
7) attachi ng the anti l ock brakes hydraul i c control
uni t (HCU) to the front suspensi on cradl e. Then
rotate the HCU rearward to al l ow access to the cra-
dl e pl ate attachi ng nut and bol t just forward of the
HCU.
(11) Remove the 10 nuts and bol ts (Fi g. 8) attach-
i ng the cradl e pl ate to the bottom of the front sus-
pensi on cradl e. Then remove the cradl e pl ate from
the cradl e.
(12) Remove the bracket (Fi g. 9) attachi ng the
power steeri ng fl ui d tubes to the front suspensi on
cradl e.
(13) Usi ng a 18mm crowfoot, (Fi g. 10) remove the
power steeri ng fl ui d pressure and return l i nes (Fi g.
10) from the power steeri ng gear.
(14) Remove the 3 bol ts and nuts (Fi g. 11) mount-
i ng the steeri ng gear to the front suspensi on cradl e.
Fig. 7 HCU Bracket Attaching Bolts
Fig. 8 Front Suspension Cradle Plate And Attaching
Bolts
Fig. 9 Power Steering Tube Bracket
Fig. 10 Power Steering Fluid Pressure And Return
Hoses At Steering Gear
Fig. 11 Steering Gear Mounting To Suspension
Cradle
NS STEERING 19 - 29
NOTE: The next step must be done to allow the
removal of the steering gear from the front suspen-
sion cradle. The steering gear can not be removed
from the vehicle with the intermediate coupler
attached to the steering gear.
(15) Lower steeri ng gear from suspensi on cradl e
enough to al l ow access to the i ntermedi ate coupl er
rol l pi n (Fi g. 12). I nstal l Remover/I nstal l er Speci al
Tool 6831A through the center of the rol l pi n, secur-
i ng wi th the knurl ed nut (Fi g. 12). Hol d threaded rod
stati onary whi l e turni ng nut, thi s wi l l pul l the rol l
pi n out of the i ntermedi ate coupl er.
(16) Separate the i ntermedi ate coupl er from the
shaft of the steeri ng gear.
(17) Remove the steeri ng gear assembl y from the
front suspensi on cradl e.
INSTALL
(1) I nstal l the steeri ng gear up i n the front sus-
pensi on cradl e, l eavi ng room to i nstal l i ntermedi ate
coupl er.
(2) Start the rol l pi n i nto the i ntermedi ate coupl er
before i nstal l i ng coupl er on steeri ng gear shaft. Start
rol l pi n i nto coupl er, usi ng a hammer and tappi ng i t
i nto the coupl er. Then i nstal l the i ntermedi ate cou-
pl er on the shaft of the steeri ng gear.
(3) I nstal l Remover/I nstal l er Speci al Tool 6831A
through the center of the rol l pi n, securi ng i t wi th
the knurl ed nut (Fi g. 13). Hol d threaded rod stati on-
ary whi l e turni ng nut, thi s wi l l pul l the rol l pi n i nto
the i ntermedi ate coupl er.
(4) I nstal l steeri ng gear assembl y on the front sus-
pensi on cradl e. I nstal l the 3 steeri ng gear to front
suspensi on cradl e mounti ng bol ts and nuts (Fi g. 11).
CAUTION: Proper torque on the steering gear to
suspension cradle mounting bolts is very impor-
tant.
(5) Ti ghten the 3 steeri ng gear to suspensi on cra-
dl e mounti ng bol ts to a torque of 183 Nm (135 ft.
l bs.).
(6) Attach the power steeri ng fl ui d pressure and
return l i nes (Fi g. 10) to the proper fi tti ngs on the
steeri ng gear. Ti ghten the power steeri ng fl ui d l i ne
tube nuts to a torque of 31 Nm (275 i n. l bs.).
(7) I nstal l ti e rod end i nto steeri ng knuckl e. Start
ti e rod end to steeri ng knuckl e attachi ng nut onto
stud of ti e rod end. Whi l e hol di ng stud of ti e rod end
stati onary usi ng a 11/32 socket, (Fi g. 5) ti ghten ti e
rod end to steeri ng knuckl e attachi ng nut. Then
usi ng a crowfoot and 11/32 socket (Fi g. 14), ti ghten
the ti e rod end attachi ng nut to a torque of 54 Nm
(40 ft. l bs.).
Fig. 12 Removing Roll Pin From Intermediate
Coupler
Fig. 13 Installing Roll Pin In Intermediate Coupler
19 - 30 STEERING NS
CAUTION: Proper torque on the cradle plate to
suspension cradle mounting bolts is very impor-
tant.
(8) I nstal l cradl e pl ate on front suspensi on cradl e
and i nstal l the 10 cradl e pl ate to cradl e attachi ng
bol ts and nuts (Fi g. 8). Ti ghten al l attachi ng bol ts to
a torque of 165 Nm (123 ft. l bs.).
(9) I nstal l the bracket (Fi g. 9) attachi ng the power
steeri ng fl ui d tubes to the front suspensi on cradl e.
CAUTION:
the steel tube at the front suspensi on cradl e (Fi g. 4).
clamp is installed on return tube past the upset
bead on the tube. Ti ghten the screw cl amp to a
torque of 2 Nm (18 i n. l bs.).
to prevent the power steering hoses from being
overheated.
(13) I nstal l the front ti re and wheel assembl i es on
vehi cl e. I nstal l the wheel l ug nuts and torque to 129
Nm (95 ft. l bs.).
(14) Lower the vehi cl e to a l evel were the i nteri or
of vehi cl e i s accessi bl e.
(15) Usi ng the i ntermedi ate coupl er, turn the front
wheel s of the vehi cl e to the l eft unti l the i ntermedi -
ate coupl er shaft i s properl y al i gned wi th the steer-
i ng col umn coupl er. Assembl e the steeri ng col umn
shaft coupl er (Fi g. 3) onto the steeri ng gear i nterme-
di ate coupl er. I nstal l steeri ng col umn coupl er to
i ntermedi ate shaft retai ni ng pi nch bol t (Fi g. 3).
Ti ghten the pi nch bol t nut to a torque of 28 Nm (250
i n. l bs.).
in the power steering system. Only use Mopar,
Power Steering Fluid or an exact equivalent prod-
uct.
(16) Fi l l power steeri ng pump fl ui d reservoi r to the
proper l evel .
(19) Rai se front wheel s of vehi cl e off the ground.
stops. Then turn the engi ne off.
cedure.
(25) Fi l l power steeri ng reservoi r to correct l evel
wi th Mopar, Power Steeri ng Fl ui d, or equi val ent.
(26) Adjust toe (Refer to Group 2 Suspensi on).
STEERING GEAR INNER TIE ROD BOOT
DISASSEMBLE
NOTE: The removal and installation of the inner tie
rod boot must be performed with the steering gear
assembly removed from the vehicle.
(1) Loosen the i nner to outer ti e rod jam nut (Fi g.
15). Remove the outer ti e rod from the i nner ti e rod.
(2) Remove nut attachi ng the outer ti e rod end to
the steeri ng knuckl e (Fi g. 16). Nut is to be
removed from tie rod end using the following
procedure, hold tie rod end stud with an 11/32
socket, while loosening and removing nut with
wrench.
Fig. 15 Inner To Outer Tie Rod Jam Nut
NS STEERING 19 - 31
(3) Remove the ti e rod end from the steeri ng
knuckl e usi ng Remover, Speci al Tool MB-991113 (Fi g.
17) or MB-990635.
(4) Remove jam nut (Fi g. 15) from i nner ti e rod.
(5) Usi ng pl i ers expand ti e rod boot, to i nner ti e
rod cl amp (Fi g. 18) and remove from steeri ng gear
boot.
(6) Remove i nner ti e rod boot to steeri ng gear
cl amp (Fi g. 19).
NOTE: After removing inner boot clamps. Use a
very small screwdriver to lift boot from its retaining
groove in steering gear. Then the boot can be
removed from steering gear.
ASSEMBLE
(1) I nstal l ti e rod boot to steeri ng gear cl amp on
ti e rod boot.
(2) I nstal l ti e rod boot and cl amp on i nner ti e rod.
(3) I nstal l ti e rod boot over steeri ng gear housi ng
and onto the end of the breather tube (Fi g. 19).
(4) Cri mp i nner ti e rod boot to steeri ng gear cl amp
usi ng Cri mper, Speci al Tool C4975A (Fi g. 20). When
i nstal l i ng cl amp, Speci al Tool C4975A must have bot-
tom bol t ti ghtened unti l thei r i s no gap between the
2 bars of the tool (Fi g. 20)
(5) Lubri cate i nner ti e rod boot groove wi th si l i -
cone type l ubri cant, then i nstal l outer boot seal to
i nner ti e rod cl amp (Fi g. 18). (Cl amp wi l l have to be
l oosened for toe adjustment.)
(6) I nstal l i nner to outer ti e rod jam nut (Fi g. 15)
on i nner ti e rod.
(7) I nstal l outer ti e rod on i nner ti e rod. Do not
ti ghten jam nut.
(8) I nstal l ti e rod end i nto the steeri ng knuckl e.
Start ti e rod end to steeri ng knuckl e attachi ng nut
onto stud of ti e rod end. Whi l e hol di ng stud of ti e rod
Fig. 16 Removing Tie Rod End Attaching Nut
Knuckle
Fig. 18 Tie Rod Boot To Tie Rod Clamp
Fig. 19 Tie Rod Boot To Steering Gear Clamp
19 - 32 STEERING NS
end stati onary, ti ghten ti e rod end to steeri ng
knuckl e attachi ng nut (Fi g. 17). Then usi ng a crow-
foot and 11/32 socket (Fi g. 21), torque ti e rod end
attachi ng nut to 54 Nm (40 ft. l bs.).
CAUTION: During this procedure do not allow the
steering gear boot to become twisted. (See Wheel
Alignment in the suspension section of this service
manual).
(9) Make toe adjustment by turni ng i nner ti e rod.
(10) Ti ghten the i nner to outer ti e rod jam nut to
75 Nm (55 ft. l bs.) torque. Lubri cate ti e rod boot
groove wi th si l i cone type l ubri cant, before i nstal l i ng
outer boot cl amp, maki ng sure boot i s not twi sted.
OUTER TIE ROD END
DISASSEMBLE
(1) Loosen i nner ti e rod to outer ti e rod jam nut
(Fi g. 22).
loosening and removing nut with wrench.
(3) Remove the ti e rod end stud from steeri ng
knuckl e arm, usi ng Remover, Speci al Tool ,
MB-991113 (Fi g. 24) or MB-990635.
(4) Remove outer ti e rod end from i nner ti e rod by
un-threadi ng i t from the i nner ti e rod.
Fig. 20 Installing Tie Rod Boot To Steering Gear
Clamp
Fig. 22 Inner To Outer Tie Rod Jam Nut
Fig. 23 Tie Rod End Attaching Nut
NS STEERING 19 - 33
ASSEMBLE
(1) I nstal l outer ti e rod onto i nner ti e rod. Make
sure jam nut (Fig. 22) is on inner tie rod.
(2) Do not ti ghten jam nut.
(3) I nstal l ti e rod end i nto the steeri ng knuckl e.
Start ti e rod end to steeri ng knuckl e attachi ng nut
onto stud of ti e rod end. Whi l e hol di ng stud of ti e rod
end stati onary, ti ghten ti e rod end to steeri ng
knuckl e attachi ng nut (Fi g. 23). Then usi ng a crow-
foot and 11/32 socket (Fi g. 25), torque ti e rod end
attachi ng nut to 54 Nm (40 ft. l bs.).
CAUTION: During this procedure do not allow the
steering gear boot to become twisted. (See Wheel
Alignment in the suspension section of this service
manual).
(4) Adjust the front Toe setti ng on the vehi cl e.
Refer to the Toe Setti ng Procedure i n Front Suspen-
si on Servi ce Procedures i n thi s group of the servi ce
manual . Refer to the Speci fi cati ons Secti on at the
end of thi s group for the desi red front Toe speci fi ca-
ti on.
(5) Ti ghten ti e rod jam nut (Fi g. 22) to 55 Nm (75
ft. l bs.) torque.
(6) Adjust the steeri ng gear to i nner ti e rod boots
at i nner ti e rod i f they became twi sted duri ng Toe
adjustment.
SPECIFICATIONS
STEERING GEAR FASTENER TORQUE
SPECIFICATIONS
DESCRIPTION TORQUE
STEERING GEAR:
To Suspensi on Cradl e Bol ts. . . .183 Nm (135 ft. l bs.)
Ti e Rod To Steeri ng
Knuckl e Nut . . . . . . . . . . . . . . .54 Nm (40 ft. l bs.)
Outer To I nner Ti e Rod
Jam Nut . . . . . . . . . . . . . . . . . .75 Nm (55 ft. l bs.)
Power Steeri ng Hose
Tube Nuts . . . . . . . . . . . . . . .31 Nm (275 i n. l bs.)
Coupl er Pi nch Bol t . . . . . . . . . . .28 Nm (250 i n. l bs.)
SUSPENSION CRADLE:
Cradl e Pl ate To Cradl e
Attachi ng Bol ts . . . . . . . . . . .165 Nm (123 ft. l bs.)
Knuckle
19 - 34 STEERING NS
SPECIAL TOOLS
POWER STEERING GEAR
Remover Tie Rod End MB991113
Remover/Installer Steering Shaft Roll Pin 6831A
P/S System Analyzer 6815
Installer Boot Clamp C-4975A
NS STEERING 19 - 35
STEERING COLUMN
INDEX
page page
STEERING COLUMN DESCRIPTION . . . . . . . . . 36
STEERING COLUMN . . . . . . . . . . . . . . . . . . . . . 38
SERVICE PROCEDURES
STEERING COLUMN SERVICE PROCEDURE
WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
STEERING COLUMN ASSEMBLY . . . . . . . . . . . . 38
SPECIFICATIONS
STEERING COLUMN FASTENER TORQUE
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . 45
STEERING COLUMN DESCRIPTION
The steeri ng col umn (Fi g. 1) has been desi gned to
be servi ced onl y as a compl ete assembl y, i f a compo-
nent of the steeri ng col umn i s defecti ve. The onl y
repl aceabl e components of the steeri ng col umn
assembl y are the key cyl i nder, i gni ti on swi tch, mul ti -
functi on swi tch, cl ockspri ng, hal o l amp, speed control
swi tches, dri ver ai rbag, tri m shrouds and steeri ng
wheel . These repl aceabl e components of the steeri ng
col umn can be servi ced wi thout requi ri ng removal of
the steeri ng col umn from the vehi cl e.
Fig. 1 Steering Column Assembly Components
19 - 36 STEERING NS
S
t
e
e
r
i
n
g
C
o
l
u
m
n
A
n
d
S
t
e
e
r
i
n
g
S
y
s
t
e
m
C
o
m
p
o
n
e
n
t
s
NS STEERING 19 - 37
STEERING COLUMN
For di agnosi s of condi ti ons rel ati ng to the steeri ng
col umn, refer to the steeri ng system di agnosi s charts,
i n the di agnosi s and testi ng secti on at the begi nni ng
of thi s group.
SERVICE PROCEDURES
STEERING COLUMN SERVICE PROCEDURE
WARNINGS
WARNING: BEFORE BEGINNING ANY SERVICE
PROCEDURES THAT INVOLVES REMOVING THE
AIR BAG. REMOVE AND ISOLATE THE NEGATIVE
(-) BATTERY CABLE (GROUND) FROM THE VEHI-
CLE BATTERY. THIS IS THE ONLY SURE WAY TO
DISABLE THE AIR BAG SYSTEM. FAILURE TO DO
THIS COULD RESULT IN ACCIDENTAL AIR BAG
DEPLOYMENT AND POSSIBLE PERSONAL INJURY.
WARNING: THE AIR BAG SYSTEM IS A SENSITIVE,
COMPLEX ELECTRO-MECHANICAL UNIT. BEFORE
ATTEMPTING TO DIAGNOSE, REMOVE OR INSTALL
THE AIR BAG SYSTEM COMPONENTS YOU MUST
FIRST DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE. FAILURE TO DO SO
COULD RESULT IN ACCIDENTAL DEPLOYMENT OF
THE AIR BAG AND POSSIBLE PERSONAL INJURY.
THE FASTENERS, SCREWS, AND BOLTS, ORIGI-
NALLY USED FOR THE AIR BAG COMPONENTS,
HAVE SPECIAL COATINGS AND ARE SPECIFI-
CALLY DESIGNED FOR THE AIR BAG SYSTEM.
THEY MUST NEVER BE REPLACED WITH ANY SUB-
STITUTES. ANYTIME A NEW FASTENER IS
NEEDED, REPLACE WITH THE CORRECT FASTEN-
ERS PROVIDED IN THE SERVICE PACKAGE OR
FASTENERS LISTED IN THE PARTS BOOKS.
BEFORE SERVICING A STEERING COLUMN
EQUIPPED WITH AN AIR BAG, REFER TO GROUP
8M, ELECTRICAL FOR PROPER AND SAFE SER-
VICE PROCEDURES.
NOTE: Safety goggles should be worn at all times
when working on steering columns.
CAUTION: Disconnect negative (ground) cable
from the battery, before servicing any column com-
ponent.
CAUTION: Do not attempt to remove the pivot pins
to disassemble the tilting mechanism. Damage will
occur.
STEERING COLUMN ASSEMBLY
To servi ce the steeri ng wheel and i ts components
or the ai r bag, refer to Group 8M, Restrai nt Systems.
Fol l ow al l WARNI NGS.
To servi ce the swi tches, refer to the appropri ate
secti on of Group 8, El ectri cal .
To repl ace the steeri ng col umn assembl y, refer to
the steeri ng col umn removal procedure.
REMOVE
(1) Make sure the front wheel s of the vehi cl e are
i n the straight ahead posi ti on before begi nni ng the
col umn removal procedure.
(2) Di sconnect negati ve (ground) cabl e from the
battery and i sol ate cabl e from battery termi nal .
(3) Remove the screws attachi ng the l ower steer-
i ng col umn cover to the i nstrument panel (Fi g. 2).
Remove the l ower tri m panel from the l ower i nstru-
ment panel .
(4) Remove the park brake pedal rel ease cabl e
from the park brake rel ease l ever (Fi g. 3).
(5) Remove the 10 bol ts attachi ng the steeri ng col -
umn cover l i ner (Fi g. 4) to the i nstrument panel .
Remove the steeri ng col umn cover l i ner from the
l ower i nstrument panel .
(6) Rotate key cyl i nder to the l ock posi ti on and
remove key. Rotate the steeri ng wheel a hal f turn to
the l eft unti l the steeri ng col umn l ock engages keep-
i ng the steeri ng col umn i n the l ocked posi ti on (Fi g.
5).
Fig. 2 Lower Steering Column Cover Attachment
Locations
19 - 38 STEERING NS
(7) Remove the 3 bol ts (1 i n each spoke of the
steeri ng wheel ) attachi ng the ai r bag modul e to the
steeri ng wheel . Remove ai r bag modul e from steeri ng
wheel .
(8) Remove wi ri ng harness connectors from ai r
bag, horn swi tch wi re, and speed control swi tches
(Fi g. 6). Remove the wi ri ng harness routi ng cl i p (Fi g.
6) from the ai r bag modul e studs.
(9) Remove the steeri ng wheel retai ni ng nut (Fi g.
7) from the steeri ng col umn shaft.
(10) Remove the steeri ng wheel damper (Fi g. 7)
from the steeri ng wheel .
CAUTION: Do not bump or hammer on steering
column or steering column shaft when removing
steering wheel from steering column shaft.
Fig. 3 Park Brake Release Cable Attachment To
Release Lever
Fig. 4 Lower Steering Column Cover Attachment
Fig. 5 Steering Wheel In Locked Position
Fig. 6 Air Bag Module Wiring Connections
Fig. 7 Steering Wheel Retaining Nut
NS STEERING 19 - 39
CAUTION: When installing steering wheel puller
bolts in steering wheel, (Fig. 8) do not thread bolt
into steering wheel more than a half inch. If bolts
are threaded into the steering wheel more than a
half inch they will contact and damage the clock-
spring.
(11) Remove the steeri ng wheel from steeri ng col -
umn shaft usi ng Pul l er, Speci al Tool , Snap-On
CJ2001JP or an equi val ent (Fi g. 8).
CAUTION: The upper and lower steering column
shrouds are held together using retaining clips.
When separating and removing the shrouds from
the steering column be careful not to break the
retaining clips off the shrouds
(12) Remove the 3 screws (Fi g. 9) attachi ng the
upper and l ower shrouds to the steeri ng col umn.
Then remove the upper and l ower shrouds (Fi g. 9)
from the steeri ng col umn.
(13) Remove the vehi cl e wi ri ng harness connectors
(Fi g. 10) from the cl ock spri ng assembl y.
CAUTION: Do not rotate the clock spring after it is
removed from the multifunction switch.
(14) Remove the cl ock spri ng from the mul ti -func-
ti on swi tch.
(15) Remove the vehi cl e wi ri ng harness connector
from the top of the mul ti -functi on swi tch (Fi g. 11).
(16) Remove the screw (Fi g. 12) attachi ng the
mul ti -functi on swi tch housi ng to the ti l t head of the
steeri ng col umn assembl y.
(17) Remove the mul ti -functi on swi tch (Fi g. 12)
from the ti l t head of the steeri ng col umn assembl y.
(18) Remove the vehi cl e wi ri ng harness connector
from the key cyl i nder hal o l i ght (Fi g. 13).
(19) Remove the 3 wi ri ng harness connectors from
the i gni ti on swi tch (Fi g. 14).
Fig. 8 Removing Steering Wheel From Steering
Column Shaft
Fig. 9 Steering Column Shrouds
Fig. 10 Wiring Harness Connections To Clock
Spring
Fig. 11 Wiring Harness Connection To Multi-
Function Switch
19 - 40 STEERING NS
(20) I f the vehi cl e i s equi pped wi th a 3 speed non-
el ectroni c transmi ssi on, remove the PRNDL actuat-
i ng cabl e from the pi n on the gear shi fter (Fi g. 15).
PRNDL actuating cable MUST be removed from
the pin on the gear shifter prior to removing
the gear selector cable from the gear shifter.
(21) Remove the attachi ng cl i p (Fi g. 15) for the
PRNDL actuati ng cabl e from the steeri ng col umn/
shi ft cabl e bracket.
(22) Remove the gear sel ector cabl e from the gear
shi fter the steeri ng col umn (Fi g. 16). Gear sel ector
cabl e i s removed from pi n on shi ft modul e by care-
fully pryi ng i t off wi th a screw dri ver (Fi g. 16).
(23) Remove the gear sel ector cabl e and i ts mount-
i ng bracket as an assembl y, from the upper mounti ng
bracket for the steeri ng col umn (Fi g. 17).
(24) Remove the i nstrument cl uster tri m bezel
(Fi g. 18) from the i nstrument panel . The tri m bezel
i s mounted to the i nstrument panel usi ng 2 attachi ng
screws and retai ni ng cl i ps.
(25) Remove the steeri ng col umn fi xed shroud
from the steeri ng col umn assembl y (Fi g. 19). Shroud
Fig. 12 Multi-Function Switch Mounting Housing
Attaching Screw
Fig. 13 Wiring Harness Connection To Halo Light
Fig. 14 Ignition Switch Wiring Harness Connections
Fig. 15 PRNDL Actuating Cable At Steering Column
Fig. 16 Gear Selector Cable Removal From Shift
Module
NS STEERING 19 - 41
i s mounted to steeri ng col umn usi ng 2 attachi ng
screws accessed from top of fi xed shroud.
(26) Di sconnect the steeri ng col umn shaft coupl er,
from the steeri ng gear i ntermedi ate steeri ng coupl er
(Fi g. 20).
(27) Loosen but do not ful l y remove the 2 nut/
washer assembl i es attachi ng the steeri ng col umn
l ower mounti ng bracket (Fi g. 21). Then remove the 2
nut/washer assembl i es attachi ng the steeri ng col umn
upper mounti ng bracket (Fi g. 21).
Fig. 17 Gear Selector Cable Mounting Bracket
Fig. 18 Instrument Cluster Trim Bezel
Fig. 19 Steering Column Fixed Shroud
Fig. 20 Steering Column Shaft To Intermediate
Coupler Attachment
Fig. 21 Steering Column Upper And Lower Mounting
Brackets
19 - 42 STEERING NS
(28) Remove steeri ng col umn assembl y from vehi -
cl e. Use care to avoi d damage to pai nt or i nteri or
tri m.
INSTALL
(1) Ensure the pl asti c mounti ng capsul es (Fi g. 22)
are i nstal l ed i n the upper mounti ng bracket of the
steeri ng col umn. Mounti ng capsul es must be
i nstal l ed as shown i n (Fi g. 22) wi th the thi cker edge
of the capsul e faci ng the top of the steeri ng col umn.
(2) I nstal l steeri ng col umn assembl y i nto i ts open-
i ng i n i nstrument panel . I nstal l the steeri ng col umn
l ower bracket so the bracket i s squarel y i nstal l ed on
i ts mounti ng studs (Fi g. 21). Then al i gn and i nstal l
steeri ng col umn upper bracket on i ts mounti ng studs
(Fi g. 21). Ti ghten the 4 steeri ng col umn assembl y
mounti ng nut/washer assembl i es to a torque of 12
Nm (105 i n. l bs.).
(3) Assembl e the steeri ng col umn shaft coupl er
(Fi g. 20) onto the steeri ng gear i ntermedi ate coupl er.
I nstal l steeri ng col umn coupl er to i ntermedi ate shaft
retai ni ng pi nch bol t (Fi g. 20). Ti ghten the pi nch bol t
nut to a torque of 28 Nm (250 i n. l bs.). I nstal l safety
pi n (Fi g. 20) i n steeri ng col umn shaft coupl er pi nch
bol t.
(4) I nstal l the gear sl ector cabl e and i ts mounti ng
bracket on the upper mounti ng bracket of the steer-
i ng col umn (Fi g. 17). I nstal l and securel y ti ghten the
mounti ng bracket attachi ng bol t.
(5) I nstal l the gear sel ector cabl e on the pi n of the
gear shi fter (Fi g. 16).
el ectroni c transmi ssi on, i nstal l the PRNDL actuati ng
cabl e on the gear shi fter pi n after the gear sel ector
cabl e i s i nstal l i ng (Fi g. 15).
el ectroni c transmi ssi on, i nstal l the attachi ng cl i p
(Fi g. 15) for the PRNDL actuati ng cabl e on the steer-
i ng col umn/shi ft cabl e bracket. Cabl e gui de tube wi l l
bow toward passenger si de of vehi cl e. Veri fy that
actuati ng cabl e i s operati ng correctl y, then sl i p the
l oop on the end of the cabl e over end of pi n on shi ft
l ever and i nstal l i n groove (Fi g. 15).
(8) I nstal l the steeri ng col umn fi xed shroud on the
steeri ng col umn assembl y (Fi g. 19). Shroud i s
mounted to steeri ng col umn usi ng 2 attachi ng screws
accessed from top of fi xed shroud.
(9) I nstal l the i nstrument cl uster tri m bezel (Fi g.
18) on the i nstrument panel . The tri m bezel i s
mounted to the i nstrument panel usi ng 2 attachi ng
screws (Fi g. 18) and retai ni ng cl i ps.
(10) I nstal l the 3 wi ri ng harness connectors on the
i gni ti on swi tch (Fi g. 14).
(11) I nstal l the vehi cl e wi ri ng harness connector
i nto the key cyl i nder hal o l i ght (Fi g. 13).
(12) I nstal l the mul ti -functi on swi tch (Fi g. 12) on
the ti l t head of the steeri ng col umn assembl y. Then
i nstal l screw (Fi g. 12) attachi ng mul ti -functi on
swi tch to ti l t head of steeri ng col umn.
on the mul ti -functi on swi tch (Fi g. 11). Be sure l atch
on connector i s ful l y engaged wi th tab on swi tch.
(14) I nstal l the cl ock spri ng on the mul ti -functi on
swi tch.
(Fi g. 10) on the cl ock spri ng assembl y.
(16) I nstal l the l ower steeri ng col umn shroud on
the ti l t head of the steeri ng col umn (Fi g. 23). I nstal l
and securel y ti ghten the screw attachi ng the l ower
shroud to the ti l t head.
(17) I nstal l the upper steeri ng col umn shroud on
the ti l t head of the steeri ng col umn (Fi g. 24). I nstal l
and securel y ti ghten the 2 screws attachi ng the
upper shroud to the l ower shroud.
Fig. 22 Mounting Capsules Correctly Installed On
Steering Column
Fig. 23 Lower Steering Column Shroud Installed
NS STEERING 19 - 43
CAUTION: Before installing the steering wheel the
clockspring must be centered. If clockspring is not
centered, the wiring in the clockspring may be over-
extended and break when the steering wheel is
rotated. Use the following procedure to center the
clockspring.
CLOCKSPRING CENTERING PROCEDURE
Depress the 2 pl asti c l ocki ng pi ns to di sengage
the l ock mechani sm (Fi g. 25).
Wi th the l ock mechani sm di sengaged, rotate the
cl ockspri ng rotor cl ockwi se unti l the rotor stops. Do
not apply excessive force.
From the end of the cl ockwi se travel , rotate the
rotor three turns countercl ockwi se. The cl ockspri ng
wi res shoul d be at the top. Engage cl ockspri ng l ock-
i ng pi ns.
From the center l ocked posi ti on, rotate the cl ock-
spri ng one-hal f addi ti onal turn countercl ockwi se. The
cl ockspri ng wi ri ng shoul d now be at the bottom. The
cl ockspri ng i s now correctl y posi ti oned for i nstal l a-
ti on of the steeri ng wheel .
CAUTION: Do not force steering wheel onto steer-
ing column shaft by driving it on. Pull steering
wheel down onto shaft using ONLY the steering
wheel retaining nut.
(18) Al i gn master spl i nes on steeri ng wheel and
steeri ng shaft, and fl ats on steeri ng wheel wi th for-
mati ons on cl ock spri ng. I nstal l the steeri ng wheel on
the steeri ng col umn shaft (Fi g. 26). Al l wi ri ng l eads
from the cl ock spri ng must be routed as shown i n
(Fi g. 26).
NOTE: Before installing the damper on the steering
wheel, inspect the damper to ensure the rubber iso-
lator on the damper is not deteriorated or damaged.
If the damper is installed with a damaged isolator a
buzz, squeak or rattle condition may develop.
(19) I nstal l the steeri ng wheel damper on the
steeri ng wheel . When damper i s i nstal l ed, i t must be
posi ti oned on the steeri ng wheel as shown i n (Fi g. 7).
(20) I nstal l the steeri ng wheel to steeri ng shaft
retai ni ng nut. Ti ghten the steeri ng wheel retai ni ng
nut to a torque of 61 Nm (45 ft. l bs.).
(21) I nstal l the wi ri ng l eads from the cl ock spri ng
on the ai r bag, horn swi tch wi re, and speed control
swi tches (Fi g. 6). Attach the wi re routi ng cl i p (Fi g. 6)
to the studs on the ai r bag modul e.
(22) I nstal l the ai r bag modul e i n the steeri ng
wheel .
Fig. 24 Upper And Lower Steering Column Shroud
Installed
Fig. 25 Clockspring Assembly
Fig. 26 Steering Wheel And Clock Spring Wire
Routing
19 - 44 STEERING NS
(23) I nstal l the 3 bol ts (1 i n each spoke of the
steeri ng wheel ) attachi ng the ai r bag modul e to the
steeri ng wheel . Ti ghten the 3 ai r bag modul e attach-
i ng nuts to a torque of 11 Nm (100 i n. l bs.).
(24) I nstal l the steeri ng col umn cover l i ner (Fi g. 4)
on the l ower i nstrument panel . I nstal l and securel y
ti ghten the 10 bol ts (Fi g. 4) attachi ng the steeri ng
col umn cover l i ner to the i nstrument panel .
(25) I nstal l the park brake pedal rel ease cabl e on
the park brake rel ease l ever i n the l ower steeri ng col -
umn cover (Fi g. 3).
(26) I nstal l the l ower steeri ng col umn tri m panel
on the l ower i nstrument panel . I nstal l and securel y
the screws attachi ng the l ower steeri ng col umn cover
to the i nstrument panel (Fi g. 2).
(27) Connect negati ve (ground) cabl e on the bat-
tery termi nal .
SPECIFICATIONS
STEERING COLUMN FASTENER TORQUE
SPECIFICATIONS
DESCRIPTION TORQUE
STEERING WHEEL:
Retai ni ng Nut . . . . . . . . . . . . . . .61 Nm (45 ft. l bs.)
STEERING COLUMN ASSEMBLY:
Mounti ng Bracket
Attachi ng Nuts . . . . . . . . . . . .12 Nm (105 i n. l bs.)
Fl ex Coupl er Pi nch Bol t . . . . . . .27 Nm (240 i n. l bs.)
Ai rbag Modul e Attachi ng Nuts . .11 Nm (100 i n. l bs.)
NS STEERING 19 - 45
STEERING
CONTENTS
page
POWER STEERING2. 5L VM DIESEL . . . . . . . 1
POWER STEERING2.5L VM DIESEL
INDEX
page page
GENERAL INFORMATION
POWER STEERING GEAR . . . . . . . . . . . . . . . . 1
POWER STEERING PUMP . . . . . . . . . . . . . . . . 1
STEERING GEAR OPERATIONRHD & LHD
VEHICLES . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
SERVICE PROCEDURES
POWER STEERING PUMP INITIAL
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 1
POWER STEERING PUMP2.5L DIESEL . . . . . 2
GENERAL INFORMATION
POWER STEERING PUMP
The power steeri ng pump used wi th the 2.5L VM
Di esel engi ne operates the same way as the power
steeri ng pump used wi th the 2.5/4.0L gasol i ne
engi nes. Refer to the Descri pti on and Operati on sec-
ti on for the 2.5/4.0L gasol i ne engi ne power steeri ng
pump for more i nformati on.
STEERING GEAR OPERATIONRHD & LHD
VEHICLES
NOTE: The power steering gear should NOT be ser-
viced or adjusted. If a malfunction or oil leak
occurs, the complete steering gear should be
replaced.
Refer to the Power Steeri ng Gear i n group 19 for
more i nformati on
POWER STEERING GEAR
SERVICE PROCEDURES
POWER STEERING PUMP INITIAL OPERATION
WARNING: THE FLUID LEVEL SHOULD BE
CHECKED WITH ENGINE OFF TO PREVENT INJURY
FROM MOVING COMPONENTS.
CAUTION: Use MOPAR Power Steering Fluid or
equivalent. Do not use automatic transmission fluid
and do not overfill.
Wi pe fi l l er cap cl ean, then check the fl ui d l evel .
The di psti ck shoul d i ndi cate COLD when the fl ui d i s
at normal temperature.
(1) Fi l l the pump fl ui d reservoi r to the proper l evel
and l et the fl ui d settl e for at l east two mi nutes.
(2) Start the engi ne and l et run for a few seconds
then turn engi ne off.
(3) Add fl ui d i f necessary. Repeat the above proce-
dure unti l the fl ui d l evel remai ns constant after run-
ni ng the engi ne.
Fig. 1 Power Steering GearRHD Vehicles
NS/GS STEERING 19 - 1
(5) Sl owl y turn the steeri ng wheel ri ght and l eft,
l i ghtl y contacti ng the wheel stops at l east 20 ti mes.
(6) Check the fl ui d l evel add i f necessary.
(7) Lower the vehi cl e, start the engi ne and turn
the steeri ng wheel sl owl y from l ock to l ock.
(8) Stop the engi ne and check the fl ui d l evel and
(9) I f the fl ui d i s extremel y foamy or mi l ky l ook-
i ng, al l ow the vehi cl e to stand a few mi nutes and
repeat the procedure.
CAUTION: Do not run a vehicle with foamy fluid for
an extended period. This may cause pump damage.
POWER STEERING PUMP2. 5L DIESEL
NOTE: The power steering pump is mounted below
the fuel pump on the left side of the engine. The
vehicle should be raised on a hoist to access the
pump from below.
REMOVAL
(1) Remove serpenti ne dri ve bel t. Refer to Group 7,
Cool i ng System, for procedure.
(2) Remove power steeri ng pump pul l ey. Use a hex
wrench to secure the power steeri ng shaft whi l e
removi ng the pul l ey bol t wi th a box wrench. (Fi g. 2)
CAUTION: Do not use an impact wrench to remove
the pump pulley this can cause rear pump seal
damage. Do not secure power steering shaft with a
wrench on the coupling to the A/C compressor
this can cause rear pump seal damage.
(3) Remove coupl i ng bol ts (2) from A/C compressor
si de of coupl i ng.
(4) Loosen A/C compressor bol ts and separate com-
pressor from bracket. Do not di sconnect A/C hoses.
(5) Remove bol ts (2) securi ng the power steeri ng
pump to the power steeri ng bracket.
(6) Di sconnect power steeri ng pump suppl y hose at
the pump and drai n fl ui d.
(7) Di sconnect power steeri ng pressure hose at the
steeri ng gear assembl y.
(8) Remove power steeri ng pump.
INSTALLATION
(1) I nstal l pump on engi ne.
(2) Ti ghten pump bracket bol ts to 47 Nm (35 ft.
l bs.).
(3) Reverse the above procedures i n steps 8
through 1 to compl ete i nstal l ati on.
(4) Add power steeri ng fl ui d and perform Power
Steeri ng Pump I ni ti al Operati on.
Fig. 2 Power Steering Pump Pulley Removal
Fig. 3 Left SIde Motor MountVM DIesel
19 - 2 STEERING NS/GS
TRANSAXLE AND POWER TRANSFER UNIT
CONTENTS
page page
31TH AUTOMATIC TRANSAXLE . . . . . . . . . . . . . . 1
41TE AUTOMATIC TRANSAXLE . . . . . . . . . . . . . 71
POWER TRANSFER UNIT . . . . . . . . . . . . . . . . . 165
31TH AUTOMATIC TRANSAXLE
INDEX
page page
GENERAL INFORMATION
31TH TRANSAXLE . . . . . . . . . . . . . . . . . . . . . . . . 2
FLUID LEVEL AND CONDITION . . . . . . . . . . . . . . 2
SELECTION OF LUBRICANT . . . . . . . . . . . . . . . . 3
SPECIAL ADDITIVES . . . . . . . . . . . . . . . . . . . . . . 3
CLUTCHES, BAND SERVOS, AND
ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . 3
FLOW CONTROL VALVES . . . . . . . . . . . . . . . . . . 3
GEARSHIFT AND PARKING LOCK CONTROLS . . 4
GOVERNOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
HYDRAULIC CONTROL SYSTEM . . . . . . . . . . . . . 3
PRESSURE REGULATING VALVES . . . . . . . . . . . 3
PRESSURE SUPPLY SYSTEM . . . . . . . . . . . . . . . 3
TORQUE CONVERTER CLUTCH SOLENOID
WIRING CONNECTOR . . . . . . . . . . . . . . . . . . . 4
TORQUE CONVERTER CLUTCH . . . . . . . . . . . . . 3
CLUTCH AND SERVO AIR PRESSURE TESTS . 15
FLUID LEAKAGE-TRANSAXLE TORQUE
CONVERTER HOUSING AREA . . . . . . . . . . . . 15
HYDRAULIC PRESSURE TESTS . . . . . . . . . . . . 13
ROAD TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
THREE SPEED TRANSAXLE DIAGNOSIS AND
TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SERVICE PROCEDURES
ALUMINUM THREAD REPAIR . . . . . . . . . . . . . . 18
FLUID AND FILTER CHANGE . . . . . . . . . . . . . . . 16
FLUID DRAIN AND REFILL . . . . . . . . . . . . . . . . . 18
FLUSHING COOLERS AND TUBES . . . . . . . . . . 18
OIL PUMP VOLUME CHECK . . . . . . . . . . . . . . . 19
FRONT PUMP OIL SEAL . . . . . . . . . . . . . . . . . . 21
PARK/NEUTRAL STARTING AND BACK-UP
LAMP SWITCH . . . . . . . . . . . . . . . . . . . . . . . . 19
TRANSAXLE AND TORQUE CONVERTER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
VEHICLE SPEED SENSOR PINION GEAR . . . . . 19
ACCUMULATOR-RECONDITION . . . . . . . . . . . . 36
DIFFERENTIAL REPAIR . . . . . . . . . . . . . . . . . . . 46
FRONT CLUTCH-RECONDITION . . . . . . . . . . . . 32
FRONT PLANETARY & ANNULUS GEAR-
RECONDITION . . . . . . . . . . . . . . . . . . . . . . . . 35
KICKDOWN SERVO (CONTROLLED LOAD)-
RECONDITION . . . . . . . . . . . . . . . . . . . . . . . . 37
LOW/REVERSE (REAR)
SERVO-RECONDITION . . . . . . . . . . . . . . . . . . 36
OIL PUMP-RECONDITION . . . . . . . . . . . . . . . . . 31
OUTPUT SHAFT REPAIR . . . . . . . . . . . . . . . . . . 43
PARKING PAWL . . . . . . . . . . . . . . . . . . . . . . . . . 42
REAR CLUTCH-RECONDITION . . . . . . . . . . . . . 33
TRANSAXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
TRANSFER SHAFT REPAIR . . . . . . . . . . . . . . . . 38
VALVE BODY RECONDITION . . . . . . . . . . . . . . . 27
VALVE BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
ADJUSTMENTS
BAND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . 51
BEARING ADJUSTMENT PROCEDURES . . . . . . 52
DIFFERENTIAL BEARING . . . . . . . . . . . . . . . . . 53
GEARSHIFT CABLE ADJUSTMENT . . . . . . . . . . 51
HYDRAULIC CONTROL PRESSURE
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . 52
OUTPUT SHAFT BEARING . . . . . . . . . . . . . . . . 52
THROTTLE PRESSURE LINKAGE
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . 51
TRANSFER SHAFT BEARING . . . . . . . . . . . . . . 54
SCHEMATICS AND DIAGRAMS
31TH TRANSAXLE HYDRAULIC SCHEMATIC . . 56
SPECIFICATIONS
31TH AUTOMATIC TRANSAXLE . . . . . . . . . . . . . 64
31TH TORQUE SPECIFICATIONS . . . . . . . . . . . 65
SPECIAL TOOLS
31TH AUTOMATIC TRANSAXLE . . . . . . . . . . . . . 66
NS TRANSAXLE AND POWER TRANSFER UNIT 21 - 1
GENERAL INFORMATION
31TH TRANSAXLE
NOTE: Safety goggles should be worn at all times
when working on these transaxles.
Thi s transaxl e combi nes torque converter, three
speed transmi ssi on, fi nal dri ve geari ng, and di fferen-
ti al i nto a front wheel dri ve system. The i denti fi ca-
ti on marki ngs and usage of the transaxl e are charted
i n Di agnosi s and Tests.
NOTE: Transaxle operation requirements are differ-
ent for each vehicle and engine combination. Some
internal parts will be different to provide for this.
Therefore, when replacing parts, refer to the seven
digit part number stamped on rear of the transaxle
oil pan flange.
Wi thi n thi s transaxl e, there are three pri mary
areas:
(1) Mai n center l i ne pl us val ve body.
(2) Transfer shaft center l i ne (i ncl udes governor
and parki ng sprag).
(3) Di fferenti al center l i ne.
(4) Center di stances between the mai n rotati ng
parts i n these three areas are hel d preci se to mai n-
tai n a l ow noi se l evel .
(5) The torque converter, transaxl e area, and di f-
ferenti al are housed i n an i ntegral al umi num di e
casti ng. The differential oil sump is common
with the transaxle sump. Separate filling of the
differential is NOT necessary.
(6) The torque converter i s attached to the crank-
shaft through a fl exi bl e dri vi ng pl ate. Cool i ng of the
converter i s accompl i shed by ci rcul ati ng the tran-
saxl e fl ui d through a remote cool er. There are two
types of cool ers used. An oi l -to-water type cool er
l ocated i n the radi ator si de tank and/or an oi l -to ai r
heat exchanger. The torque converter assembl y i s a
seal ed uni t that cannot be di sassembl ed.
(7) The transaxl e fl ui d i s fi l tered by an i nternal fi l -
ter attached to the l ower si de of the val ve body
assembl y.
(8) Engi ne torque i s transmi tted to the torque con-
verter then, through the i nput shaft to mul ti pl e-di sc
cl utches i n the transaxl e. The power fl ow depends on
the appl i cati on of the cl utches and bands. Refer to
El ements i n Use Chart i n Di agnosi s and Tests sec-
ti on.
(9) The transaxl e consi sts of:
Two mul ti pl e-di sc cl utches
An overrunni ng cl utch
Two servos
A hydraul i c accumul ator
Two bands
Two pl anetary gear sets
Thi s provi des three forward rati os and a reverse
rati o. The common sun gear of the pl anetary gear
sets i s connected to the front cl utch by a dri vi ng
shel l . The dri ve shel l i s spl i ned to the sun gear and
front cl utch retai ner. The hydraul i c system consi sts
of an oi l pump, and a si ngl e val ve body whi ch con-
tai ns al l of the val ves except the governor val ves.
The transaxl e sump and di fferenti al sump are both
vented through the di psti ck. Output torque from the
mai n center l i ne i s del i vered through hel i cal gears to
the transfer shaft. Thi s gear set i s a factor of the
fi nal dri ve (axl e) rati o. The shaft al so carri es the gov-
ernor and parki ng sprag. An i ntegral hel i cal gear on
the transfer shaft dri ves the di fferenti al ri ng gear.
The fi nal dri ve geari ng i s compl eted wi th one of two
gear rati os of 2.98 or 3.19 dependi ng on model and
appl i cati on.
FLUID LEVEL AND CONDITION
NOTE: The transmission and differential sump have
a common oil sump with a communicating opening
between the two.
The torque converter fi l l s i n both the P Park and N
Neutral posi ti ons. Pl ace the sel ector l ever i n P Park
to be sure that the fl ui d l evel check i s accurate. The
engine should be running at idle speed for at
least one minute, with the vehicle on level
ground. This will assure complete oil level sta-
bilization between differential and transmis-
sion. The fl ui d shoul d be at normal operati ng
temperature (approxi matel y 82 C. or 180 F.). The
fl ui d l evel i s correct i f i t i s i n the HOT regi on (cross-
hatched area) on the di psti ck.
Low fl ui d l evel can cause a vari ety of condi ti ons
because i t al l ows the pump to take i n ai r al ong wi th
the fl ui d. As i n any hydraul i c system, ai r bubbl es
make the fl ui d spongy, therefore, pressures wi l l be
l ow and bui l d up sl owl y.
I mproper fi l l i ng can al so rai se the fl ui d l evel too
hi gh. When the transaxl e has too much fl ui d, the
gears churn up foam and cause the same condi ti ons
whi ch occur wi th a l ow fl ui d l evel .
I n ei ther case, the ai r bubbl es can cause overheat-
i ng, fl ui d oxi dati on, and varni shi ng. Thi s can i nter-
fere wi th normal val ve, cl utch, and servo operati on.
Foami ng can al so resul t i n fl ui d escapi ng from the
transaxl e di psti ck where i t may be mi staken for a
l eak.
Al ong wi th fl ui d l evel , i t i s i mportant to check the
condi ti on of the fl ui d. When the fl ui d smel l s burned,
and i s contami nated wi th metal or fri cti on materi al
parti cl es, a compl ete transaxl e overhaul i s needed.
Be sure to exami ne the fl ui d on the di psti ck cl osel y.
21 - 2 TRANSAXLE AND POWER TRANSFER UNIT NS
I f there i s any doubt about i ts condi ti on, drai n out a
sampl e for a doubl e check.
SELECTION OF LUBRICANT
I t i s i mportant that the proper l ubri cant be used i n
these transmi ssi ons. Mopar ATF PLUS 3 (Automati c
Transmi ssi on Fl ui d- type 7176) shoul d be used to ai d
i n ensuri ng opti mum transmi ssi on performance. I t i s
i mportant that the transmi ssi on fl ui d be mai ntai ned
at the prescri bed l evel usi ng the recommended fl ui ds.
SPECIAL ADDITIVES
Chrysl er Corporati on does not recommend the
addi ti on of any fl ui ds to the transmi ssi on, other than
fl ui d l i sted above. An excepti on to thi s pol i cy i s the
use of speci al dyes to ai d i n detecti ng fl ui d l eaks. The
use of transmi ssi on seal ers shoul d be avoi ded, si nce
they may adversel y affect seal s.
TORQUE CONVERTER CLUTCH
A torque converter cl utch i s standard on al l vehi -
cl es. The torque converter cl utch i s acti vated onl y i n
di rect dri ve and i s control l ed by the engi ne el ectron-
i cs. A sol enoi d on the val ve body, i s powered by the
powertrai n control modul e to acti vate torque con-
verter cl utch.
HYDRAULIC CONTROL SYSTEM
The hydraul i c control system makes the transaxl e
ful l y automati c, and has four i mportant functi ons to
perform. The components of any automati c control
system may be grouped i nto the fol l owi ng basi c
groups:
The pressure suppl y system, the pressure regul at-
i ng val ves, the fl ow control val ves, the cl utches, and
band servos.
Taki ng each of these basi c groups or systems i n
turn, the control system may be descri bed as fol l ows:
PRESSURE SUPPLY SYSTEM
The pressure suppl y system consi sts of an oi l pump
dri ven by the engi ne through the torque converter.
The si ngl e pump furni shes pressure for al l the
hydraul i c and l ubri cati on requi rements. Oil pump
housing assemblies are available with prese-
lected pump gears.
PRESSURE REGULATING VALVES
The pressure regul ati ng val ve control s l i ne pres-
sure dependent on throttl e openi ng. The governor
val ve transmi ts regul ated pressure to the val ve body
(i n conjuncti on wi th vehi cl e speed) to control upshi ft
and downshi ft.
The throttl e val ve transmi ts regul ated pressure to
the transaxl e (dependent on throttl e posi ti on) to con-
trol upshi ft and downshi ft.
FLOW CONTROL VALVES
The manual val ve provi des the di fferent transaxl e
dri ve ranges as sel ected by the vehi cl e operator.
The 1-2 shi ft val ve automati cal l y shi fts the tran-
saxl e from fi rst to second or from second to fi rst,
dependi ng on the vehi cl e operati on.
The 2-3 shi ft val ve automati cal l y shi fts the tran-
saxl e from second to thi rd or from thi rd to second
dependi ng on the vehi cl e operati on.
The ki ckdown val ve makes possi bl e a forced down-
shi ft from thi rd to second, second to fi rst, or thi rd to
fi rst (dependi ng on vehi cl e speed). Thi s can be done
by depressi ng the accel erator pedal past the detent
feel near wi de open throttl e.
The shuttl e val ve has two separate functi ons and
performs each i ndependentl y of the other. The fi rst i s
provi di ng fast rel ease of the ki ckdown band, and
smooth front cl utch engagement when a l i ft-foot
upshi ft from second to thi rd i s made. The second
functi on i s to regul ate the appl i cati on of the ki ck-
down servo and band when maki ng thi rd to second
ki ckdown.
The by-pass val ve provi des for smooth appl i cati on
of the ki ckdown band on 1-2 upshi fts.
The torque converter cl utch sol enoi d al l ows for the
el ectroni c control of the torque converter cl utch. I t
al so di sengages the torque converter at cl osed throt-
tl e. Thi s i s done duri ng engi ne warm-up, and part-
throttl e accel erati on.
The swi tch val ve di rects oi l to appl y the torque
converter cl utch i n one posi ti on. The swi tch val ve
rel eases the torque converter cl utch i n the other posi -
ti on.
CLUTCHES, BAND SERVOS, AND ACCUMULATOR
The front and rear cl utch pi stons, and both servo
pi stons are moved hydraul i cal l y to engage the
cl utches and appl y the bands. The pi stons are
rel eased by spri ng tensi on when hydraul i c pressure
i s rel eased. On the 2-3 upshi ft, the ki ckdown servo
pi ston i s rel eased by spri ng tensi on and hydraul i c
pressure.
The accumul ator control s the hydraul i c pressure
on the appl y si de of the ki ckdown servo duri ng the
1-2 upshi ft; thereby, cushi oni ng the ki ckdown band
appl i cati on at any throttl e posi ti on.
GEARSHIFT AND PARKING LOCK CONTROLS
The transaxl e i s control l ed by a l ever type gear-
shi ft i ncorporated wi thi n the steeri ng col umn. The
control has si x sel ector l ever posi ti ons: P (park), R
(reverse), N (neutral ), and D (dri ve), 2 (second), and
1 (fi rst). The parki ng l ock i s appl i ed by movi ng the
sel ector l ever past a gate to the P posi ti on. Do not
apply the parking lock until the vehicle has
stopped; otherwise, a severe ratchet noise will
occur.
TORQUE CONVERTER CLUTCH SOLENOID WIRING
CONNECTOR
I f wi ri ng connector i s unpl ugged, the torque con-
verter wi l l not engage (Fi g. 1) .
GOVERNOR
The governor may be servi ced by removi ng the
transaxl e oi l pan and val ve body assembl y. The gov-
ernor may be unbol ted from the governor support
and removed from the transaxl e for recondi ti oni ng or
repl acement.
When cl eani ng or assembl i ng the governor, make
sure the governor val ves move freel y i n the bores of
the governor body.
THREE SPEED TRANSAXLE DIAGNOSIS AND
TESTS
Automati c transaxl e mal functi ons may be caused
by four general condi ti ons:
(1) Poor engi ne performance
(2) I mproper adjustments
(3) Hydraul i c mal functi ons
(4) Mechani cal mal functi ons
Di agnosi s of these probl ems shoul d al ways begi n
by checki ng the easi l y accessi bl e vari abl es; fl ui d l evel
and condi ti on, gearshi ft cabl e adjustment, and throt-
tl e pressure cabl e adjustment. Then perform a road
test to determi ne i f the probl em has been corrected
or that more di agnosi s i s necessary. I f the probl em
exi sts after the prel i mi nary tests and correcti ons are
compl eted, hydraul i c pressure tests shoul d be per-
formed
31TH HYDRAULIC TROUBLE CODE CHARTS
The fol l owi ng charts shoul d be used to hel p di ag-
nose hydraul i c or mechani cal faul ts i n the transaxl e .
ROAD TEST
Pri or to performi ng a road test, check the fl ui d
l evel , and control cabl e adjustments.
Duri ng the road test, the transaxl e shoul d be oper-
ated i n each posi ti on to check for sl i ppi ng and any
vari ati on i n shi fti ng.
I f vehi cl e operates at hi gh speeds, but has poor
accel erati on, the converters overrunni ng cl utch may
be sl i ppi ng. I f accel erati on i s normal , but hi gh throt-
tl e openi ng i s needed for hi gh speeds, the stator
cl utch may have sei zed.
Observe cl osel y for sl i ppi ng or engi ne speed fl are-
up. Sl i ppi ng or fl are-up i n any gear usual l y i ndi cates
cl utch, band, or overrunni ng cl utch probl ems. I f the
condi ti on i s far advanced, an overhaul wi l l probabl y
be necessary to restore normal operati on.
I n most cases, the cl utch or band that i s sl i ppi ng
can be determi ned by noti ng the transaxl e operati on
i n al l sel ector posi ti ons. Then compari ng whi ch i nter-
nal uni ts are appl i ed i n those posi ti ons. The El e-
ments i n Use Chart provi des a basi s for road test
anal ysi s .
The rear cl utch i s appl i ed i n both the D fi rst gear
and 1 fi rst gear posi ti ons. Al so the overrunni ng
cl utch i s appl i ed i n D fi rst gear and the l ow/reverse
band i s appl i ed i n 1 fi rst gear posi ti on. I f the tran-
saxl e sl i ps i n D range fi rst gear, but does not sl i p i n
1 fi rst gear, the overrunni ng cl utch i s sl i ppi ng. Si mi -
l arl y, i f the transaxl e sl i ps i n any two forward gears,
the rear cl utch i s sl i ppi ng.
Usi ng the same procedure, the rear cl utch and
front cl utch are appl i ed i n D thi rd gear. I f the tran-
saxl e sl i ps i n thi rd gear, ei ther the front cl utch or the
rear cl utch i s sl i ppi ng. By sel ecti ng another gear
whi ch does not use one of those uni ts, the uni t whi ch
i s sl i ppi ng can be determi ned. I f the transaxl e al so
sl i ps i n reverse, the front cl utch i s sl i ppi ng. I f the
transaxl e does not sl i p i n reverse, the rear cl utch i s
sl i ppi ng.
The process of el i mi nati ng can be used to detect
any uni t whi ch sl i ps and to confi rm proper operati on
of good uni ts. Road testi ng can usual l y di agnose sl i p-
pi ng uni ts. Al though the actual cause of the probl em
Fig. 1 Torque Converter Clutch Solenoid Wiring
Connector
Diagnosis Guide
Diagnosis Guide
Diagnosis Guide
Diagnosis Guide
Diagnosis Guide
Diagnosis Guide
Diagnosis Guide
Diagnosis Guide
may not be detected. Practi cal l y any condi ti on can be
caused by l eaki ng hydraul i c ci rcui ts or sti cki ng
val ves.
Therefore, unl ess the condi ti on i s obvi ous, the tran-
saxl e shoul d never be di sassembl ed unti l hydraul i c
pressure tests have been performed.
HYDRAULIC PRESSURE TESTS
Pressure testi ng i s a very i mportant step i n the
di agnosti c procedure. These tests usual l y reveal the
cause of most transaxl e probl ems.
Before performi ng pressure tests, be certai n that
fl ui d l evel and condi ti on, and control cabl e adjust-
ments have been checked and approved. Fl ui d must
be at operati ng temperature (150 to 200 degrees F.).
I nstal l an engi ne tachometer, rai se vehi cl e on hoi st
whi ch al l ows front wheel s to turn, and posi ti on
tachometer so i t can be read.
Di sconnect throttl e cabl e and shi ft cabl e from tran-
saxl e l evers so they can be control l ed from outsi de
the vehi cl e.
Attach 150 psi gauges to ports requi red for test
bei ng conducted. A 300 psi gauge (C-3293) i s requi red
for reverse pressure test at rear servo.
Test port l ocati ons are shown i n (Fi g. 2) .
TEST ONE (SELECTOR IN 1)
(1) Attach gauges to l i ne and l ow-reverse ports.
(2) Operate engi ne at 1000 rpm for test.
(3) Move sel ector l ever on transaxl e al l the way
rearward (1 posi ti on).
(4) Read pressures on both gauges as throttl e l ever
on transaxl e i s moved from ful l cl ockwi se posi ti on to
ful l countercl ockwi se posi ti on.
(5) Li ne pressure shoul d read 52 to 58 psi wi th
throttl e l ever cl ockwi se. Pressure shoul d gradual l y
i ncrease, as l ever i s moved countercl ockwi se, to 80 to
88 psi .
(6) Low-reverse pressure shoul d read the same as
l i ne pressure wi thi n 3 psi .
(7) Thi s tests pump output, pressure regul ati on,
and condi ti on of rear cl utch and rear servo hydraul i c
ci rcui ts.
TEST TWO (SELECTOR IN 2)
(1) Attach one gauge to l i ne pressure port and tee
another gauge i nto l ower cool er l i ne fi tti ng. Thi s wi l l
al l ow l ubri cati on pressure readi ngs to be taken..
(3) Move sel ector l ever on transaxl e one detent for-
ward from ful l rearward posi ti on. Thi s i s sel ector 2
posi ti on.
i ncrease, as l ever i s moved countercl ockwi se, to 80 to
88 psi .
(6) Lubri cati on pressure shoul d be 10 to 25 psi
wi th l ever cl ockwi se and 10 to 35 psi wi th l ever ful l
countercl ockwi se.
and condi ti on of rear cl utch and l ubri cati on hydraul i c
ci rcui ts.
TEST THREE (SELECTOR IN D)
(1) Attach gauges to l i ne and ki ckdown rel ease
ports.
(3) Move sel ector l ever on transaxl e two detents
forward from ful l rearward posi ti on. Thi s i s sel ector
D posi ti on.
ELEMENTS IN USE AT EACH POSITION OF THE SELECTOR LEVER
i ncrease, as l ever i s moved countercl ockwi se to 80 to
88 psi .
(6) Ki ckdown rel ease i s pressuri zed onl y i n di rect
dri ve and shoul d be same as l i ne pressure wi thi n 3
psi , up to ki ckdown poi nt.
and condi ti on of rear cl utch, front cl utch, and
hydraul i c ci rcui ts.
TEST FOUR (SELECTOR IN REVERSE)
(1) Attach 300 psi gauge to l ow-reverse port.
(3) Move sel ector l ever on transaxl e four detents
forward from ful l rearward posi ti on. Thi s i s sel ector
R posi ti on.
(4) Low-reverse pressure shoul d read 180 to 220
psi wi th throttl e l ever cl ockwi se. Pressure shoul d
gradual l y i ncrease, as l ever i s moved countercl ock-
wi se to 260 to 300 psi .
and condi ti on of front cl utch and rear servo hydraul i c
ci rcui ts.
(6) Move sel ector l ever on transaxl e to D posi ti on
to check that l ow-reverse pressure drops to zero.
(7) Thi s tests for l eakage i nto rear servo, due to
case porosi ty, whi ch can cause reverse band burn out.
TEST RESULT INDICATIONS
(1) I f proper l i ne pressure, mi ni mum to maxi mum,
i s found i n any one test, the pump and pressure reg-
ul ator are worki ng properl y.
(2) Low pressure i n D, 1, and 2 but correct pres-
sure i n R i ndi cates rear cl utch ci rcui t l eakage.
(3) Low pressure i n D and R but correct pressure
i n 1 i ndi cates front cl utch ci rcui t l eakage.
Fig. 2 Test Port Locations
Fig. 3 Governor Pressure Tap
(4) Low pressure i n R and 1 but correct pressure
i n 2 i ndi cates rear servo ci rcui t l eakage.
(5) Low l i ne pressure i n al l posi ti ons i ndi cates a
defecti ve pump, a cl ogged fi l ter, or a stuck pressure
regul ator val ve.
GOVERNOR PRESSURE
Test onl y i f transaxl e shi fts at wrong vehi cl e
speeds when throttl e cabl e i s correctl y adjusted.
(1) Connect a 0-150 psi pressure gauge to governor
pressure take-off poi nt. I t i s l ocated at l ower ri ght
si de of case, bel ow di fferenti al cover.
(2) Operate transaxl e i n thi rd gear to read pres-
sures. The governor pressure shoul d respond
smoothl y to changes i n mph and shoul d return to 0
to 3 psi when vehi cl e i s stopped. Hi gh pressure at
standsti l l (above 3 psi ) wi l l prevent the transaxl e
from downshi fti ng.
THROTTLE PRESSURE
No gauge port i s provi ded for throttl e pressure.
I ncorrect throttl e pressure shoul d be suspected i f
part throttl e upshi ft speeds are ei ther del ayed or
occur too earl y i n rel ati on to vehi cl e speeds. Engi ne
runaway on shi fts can al so be an i ndi cator of l ow
throttl e pressure setti ng, or mi sadjusted throttl e
cabl e.
I n no case shoul d throttl e pressure be adjusted
unti l the transaxl e throttl e cabl e adjustment has
been veri fi ed to be correct.
CLUTCH AND SERVO AIR PRESSURE TESTS
A no dri ve condi ti on mi ght exi st even wi th correct
fl ui d pressure, because of i noperati ve cl utches or
bands. The i noperati ve uni ts, cl utches, bands, and
servos can be l ocated through a seri es of tests. Thi s
i s done by substi tuti ng ai r pressure for fl ui d pressure
(Fi g. 4) .
The front and rear cl utches, ki ckdown servo, and
l ow-reverse servo may be tested by appl yi ng ai r pres-
sure to thei r respecti ve passages. To make ai r pres-
sure tests, proceed as fol l ows:
NOTE: Compressed air supply must be free of all
dirt or moisture. Use a pressure of 30 psi.
Remove oi l pan and val ve body. Refer to Val ve
Body for removal procedure.
FRONT CLUTCH
Appl y ai r pressure to front cl utch appl y passage
and l i sten for a dul l thud whi ch i ndi cates that front
cl utch i s operati ng. Hol d ai r pressure on for a few
seconds and i nspect system for excessi ve oi l l eaks.
REAR CLUTCH
Appl y ai r pressure to rear cl utch appl y passage
and l i sten for a dul l thud whi ch i ndi cates that rear
cl utch i s operati ng. Al so i nspect for excessi ve oi l
l eaks. I f a dul l thud cannot be heard i n the cl utches,
pl ace fi nger ti ps on cl utch housi ng and agai n appl y
ai r pressure. Movement of pi ston can be fel t as the
cl utch i s appl i ed.
KICKDOWN SERVO (FRONT)
Di rect ai r pressure i nto KI CKDOWN SERVO ON
passage. Operati on of servo i s i ndi cated by a ti ghten-
i ng of front band. Spri ng tensi on on servo pi ston
shoul d rel ease the band.
LOW AND REVERSE SERVO (REAR)
Di rect ai r pressure i nto LOW-REVERSE SERVO
APPLY passage. Operati on of servo i s i ndi cated by a
ti ghteni ng of rear band. Spri ng tensi on on servo pi s-
ton shoul d rel ease the band.
I f cl utches and servos operate properl y, no upshi ft
i ndi cates that a mal functi on exi sts i n the val ve body.
FLUID LEAKAGE-TRANSAXLE TORQUE
CONVERTER HOUSING AREA
(1) Check for source of l eakage.
(2) Si nce fl ui d l eakage near the torque converter
area may be from an engi ne oi l l eak, the area shoul d
be checked cl osel y. Factory fi l l fl ui d i s dyed red and,
therefore, can be di sti ngui shed from engi ne oi l .
(3) Pri or to removi ng the transaxl e, perform the
fol l owi ng checks:
(4) When l eakage i s determi ned to ori gi nate from
the transaxl e, check fl ui d l evel pri or to removal of
the transaxl e and torque converter.
(5) Hi gh oi l l evel can resul t i n oi l l eakage out the
vent i n the di psti ck. I f the fl ui d l evel i s hi gh, adjust
to proper l evel .
(6) After performi ng thi s operati on, i nspect for
l eakage. I f a l eak persi sts, perform the fol l owi ng
operati on on the vehi cl e. Thi s wi l l determi ne i f the
torque converter or transaxl e i s l eaki ng.
TORQUE CONVERTER LEAKAGE
Possi bl e sources of torque converter l eakage are:
Torque converter wel d l eaks at the outsi de di am-
eter (peri pheral ) wel d.
Torque converter hub wel d.
Torque converter i mpel l er shel l cracked adjacent
to hub.
At dri ve l ug wel ds.
NOTE: Hub weld is inside and not visible. Do not
attempt to repair. Replace torque converter.
SERVICE PROCEDURES
FLUID AND FILTER CHANGE
When the factory fi l l fl ui d i s changed, onl y fl ui ds
l abel ed MOPAR ATF PLUS 3 (Automati c Transmi s-
si on fl ui d) Type 7176 shoul d be used.
I f the transaxl e i s di sassembl ed for any reason, the
fl ui d and fi l ter shoul d be changed.
30,000 MILE TRANSAXLE OIL CHANGE
When a vehi cl e attai ns 30,000 mi l es on i ts odome-
ter i t i s recommended that the transaxl e oi l be
changed. To change the oi l , use the procedure that
fol l ows:
I t i s recommended that a transaxl e fl ui d exchanger
(ATF 2000+ or equi val ent) be used to repl ace the
used fl ui d i n the transaxl e. I f a fl ui d exchanger i s not
avai l abl e use a fl ui d sucti on pump (Vacul a or equi v-
al ent) to draw the fl ui d out of the di psti ck tube. I f a
fl ui d sucti on pump i s not avai l abl e remove the oi l
pan and drai n the fl ui d.
CAUTION: Chrysler Corporation does not recom-
mend using any fluid exchanger that introduces
additives into the transaxle.
TRANSAXLE FLUID EXCHANGER METHOD
(1) To perform the transaxl e fl ui d exchange, the
transaxl e must be at operati ng temperature. Dri ve
the vehi cl e ti l l i t reaches ful l operati ng temperature.
(2) Veri fy that the fi l l tank on the transaxl e fl ui d
exchanger (ATF 2000+ or equi val ent) i s cl ean and
dry.
(3) Fi l l the tank to the recommended fi l l capaci ty
wi th Mopar ATF Pl us 3 Type 7176.
(4) Hookup the vehi cl e to the machi ne fol l owi ng
the manufacturers i nstructi ons. Perform the
exchange procedure fol l owi ng the i nstructi ons pro-
vi ded wi th the machi ne.
(5) Once machi ne has compl eted the fl ui d
exchange. Check the fl ui d l evel and condi ti on and fi l l
to proper l evel wi th Mopar ATF Pl us 3 Type 7176.
NOTE: Verify that the transaxle cooler lines are
tightened to proper specifications. Cooler line
torque specification is 2 Nm (18 in. lbs.).
DIPSTICK TUBE FLUID SUCTION METHOD
(1) When performi ng the fl ui d sucti on method,
make sure the transaxl e i s at ful l operati ng temper-
ature.
Fig. 4 Air Pressure Tests
(2) To perform the di psti ck tube fl ui d sucti on
method, use a sui tabl e fl ui d sucti on devi ce (Vacul a
or equi val ent).
(3) I nsert the fl ui d sucti on l i ne i nto the di psti ck
tube.
NOTE: Verify that the suction line is inserted to the
lowest point of the transaxle oil pan. This will
ensure complete evacuation of the fluid in the pan.
(4) Fol l ow the manufacturers recommended proce-
dure and evacuate the fl ui d from the transaxl e.
(5) Remove the sucti on l i ne from the di psti ck tube.
(6) Add 4 Quarts of Mopar ATF Pl us 3 Type 7176
transaxl e fl ui d.
(7) Start the engi ne and al l ow i t to i dl e for a mi n-
i mum of one mi nute. Wi th the parki ng brake appl i ed,
press your foot on the servi ce brake and cycl e the
transaxl e from park to al l gear posi ti ons endi ng i n
neutral or park.
(8) Check the transaxl e fl ui d l evel and add an
appropri ate amount to bri ng the transaxl e fl ui d l evel
to 3mm (1/8 i n.) bel ow the ADD mark on the di p-
sti ck.
(9) Recheck the fl ui d l evel after the transaxl e i s at
normal operati ng temperature. The l evel shoul d be i n
the HOT range.
TRANSAXLE OIL PAN DROP METHOD
Thi s procedure i nvol ves removi ng the transaxl e oi l
pan to drai n the transaxl e fl ui d.
(1) Bri ng the vehi cl e up to normal operati ng tem-
perature. Dri ve the vehi cl e a mi ni mum of 10 mi l es.
(2) Rai se the vehi cl e on the hoi st.
(3) Loosen the transaxl e oi l pan and drai n the
fl ui d i nto a sui tabl e contai ner.
(4) Remove the pan and cl ean al l seal ant from the
pan and transaxl e mati ng surfaces. Cl ean the mag-
net and the i nsi de of the pan.
(5) Appl y a 1/8 i nch bead of Mopar RTV Seal ant to
the mounti ng fl ange of the transaxl e oi l pan. Appl y
RTV Seal ant to the undersi de of the attachi ng bol ts.
Attach the oi l pan to the transaxl e. Ti ghten the bol ts
to 19 Nm (165 i n. l bs.).
(6) Lower the vehi cl e and add 4 Quarts of Mopar
ATF Pl us 3 Type 7176 transaxl e fl ui d.
neutral or park.
sti ck.
the HOT range. Dri ve the vehi cl e a mi ni mum of 10
mi l es.
(11) Check for l eaks around the transaxl e oi l pan
seal i ng surfaces.
(12) Recheck the fl ui d l evel . The l evel shoul d be i n
the HOT range.
SEVERE USAGE SERVICE
I f the vehi cl e exhi bi ts any of the fol l owi ng symp-
toms, i t i s recommended that the transaxl e oi l and
fi l ter be repl aced.
Transaxl e oi l di scol ored
Transaxl e oi l has hi gh mi l eage
Oi l feel s gri my when rubbed between fi ngerti ps
Poor shi ft qual i ty
Del ayed gear engagement
Vehi cl e shudder between shi fts
TRANSAXLE OIL AND FILTER REPLACEMENT
Thi s procedure i nvol ves changi ng the transaxl e
fl ui d and fi l ter, dri vi ng the vehi cl e for 10 mi l es and
changi ng the transaxl e fl ui d a second ti me.
(5) Separate the fi l ter and O-ri ng from the val ve
body. I nspect the O-ri ng for cuts or i mproper i nstal -
l ati on. Thi s coul d l ead to del ayed garage shi fts.
(6) I nstal l a new fi l ter. Repl ace the O-ri ng as nec-
essary.
to 19 Nm (165 i n. l bs.).
neutral or park.
sti ck.
(11) Recheck the fl ui d l evel after the transaxl e i s
at normal operati ng temperature. The l evel shoul d be
i n the HOT range. Dri ve the vehi cl e a mi ni mum of
10 mi l es.
(13) Remove the pan and cl ean al l seal ant from
the pan and transaxl e mati ng surfaces. Cl ean the
magnet and the i nsi de of the pan.
(14) Separate the fi l ter from the val ve body to
al l ow addi ti onal fl ui d to drai n from the transaxl e.
I nspect the fi l ter O-ri ng for any damage and repl ace
as necessary.
(15) After the transaxl e has stopped drai ni ng,
rei nstal l the fi l ter and O-ri ng.
(16) Appl y a 1/8 i nch bead of Mopar RTV Seal ant
to the mounti ng fl ange of the transaxl e oi l pan.
Appl y RTV Seal ant to the undersi de of the attachi ng
bol ts. Attach the oi l pan to the transaxl e. Ti ghten the
neutral or park.
sti ck.
i n the HOT range.
FLUID DRAIN AND REFILL
(1) Rai se vehi cl e on a hoi st (See Group 0, Lubri ca-
ti on). Pl ace a drai n contai ner wi th a l arge openi ng,
under transaxl e oi l pan.
(2) Loosen pan bol ts and tap the pan at one corner
to break i t l oose al l owi ng fl ui d to drai n, then remove
the oi l pan.
(3) I nstal l a new fi l ter and gasket on bottom of the
val ve body and ti ghten retai ni ng screws to 5 Nm (40
i nch-pounds).
(4) Cl ean the oi l pan and magnet. Rei nstal l pan
usi ng new seal ant. Ti ghten oi l pan bol ts to 19 Nm
(165 i n. l bs.).
(5) Pour four quarts of Mopar ATF PLUS 3 (Auto-
mati c Transmi ssi on Fl ui d) Type 7176 through the
di psti ck openi ng.
(6) Start engi ne and al l ow to i dl e for at l east one
mi nute. Then, wi th parki ng and servi ce brakes
appl i ed, move sel ector l ever momentari l y to each
posi ti on, endi ng i n the park or neutral posi ti on.
(7) Add suffi ci ent fl ui d to bri ng l evel to 1/8 i nch
bel ow the ADD mark.
(8) Recheck fl ui d l evel after transaxl e i s at normal
operati ng temperature. The l evel shoul d be i n the
HOT regi on.
ALUMINUM THREAD REPAIR
Damaged or worn threads i n the al umi num transaxl e
case and val ve body can be repai red by the use of Hel i -
Coi l s, or equi val ent. Thi s repai r consi sts of dri l l i ng out
the worn-out damaged threads. Then tappi ng the hol e
wi th a Hel i -Coi l tap, or equi val ent, and i nstal l i ng a
Hel i -Coi l i nsert, or equi val ent, i nto the hol e. Thi s
bri ngs the hol e back to i ts ori gi nal thread si ze.
Hel i -Coi l , or equi val ent, tool s and i nserts are readi l y
avai l abl e from most automoti ve parts suppl i ers.
FLUSHING COOLERS AND TUBES
When a transaxl e fai l ure has contami nated the
fl ui d, the oi l cool er(s) must be fl ushed. The cool er
bypass val ve i n the transaxl e must be repl aced al so.
The torque converter must al so be repl aced wi th an
exchange uni t. Thi s wi l l ensure that metal parti cl es
or sl udged oi l are not l ater transferred back i nto the
recondi ti oned (or repl aced) transaxl e.
The recommended procedure for fl ushi ng the cool -
ers and tubes i s to use Tool 6906A Cool er Fl usher.
WARNING: WEAR PROTECTIVE EYEWEAR THAT
MEETS THE REQUIREMENTS OF OSHA AND ANSI
Z87.11968. WEAR STANDARD INDUSTRIAL RUB-
BER GLOVES.
KEEP LIGHTED CIGARETTES, SPARKS, FLAMES,
AND OTHER IGNITION SOURCES AWAY FROM THE
AREA TO PREVENT THE IGNITION OF COMBUSTI-
BLE LIQUIDS AND GASES. KEEP A CLASS (B) FIRE
EXTINGUISHER IN THE AREA WHERE THE
FLUSHER WILL BE USED.
KEEP THE AREA WELL VENTILATED.
DO NOT LET FLUSHING SOLVENT COME IN CON-
TACT WITH YOUR EYES OR SKIN: IF EYE CONTAM-
INATION OCCURS, FLUSH EYES WITH WATER FOR
15 TO 20 SECONDS. REMOVE CONTAMINATED
CLOTHING AND WASH AFFECTED SKIN WITH
SOAP AND WATER. SEEK MEDICAL ATTENTION.
COOLER FLUSH USING TOOL 6906A
(1) Remove cover pl ate fi l l er pl ug on Tool 6906A.
Fi l l reservoi r 1/2 to 3/4 ful l of fresh fl ushi ng sol uti on.
Fl ushi ng sol vents are petrol eum based sol uti ons gen-
eral l y used to cl ean automati c transmi ssi on compo-
nents. DO NOT use sol vents contai ni ng aci ds, water,
gasol i ne, or any other corrosi ve l i qui ds.
(2) Rei nstal l fi l l er pl ug on Tool 6906A.
(3) Veri fy pump power swi tch i s turned OFF. Con-
nect red al l i gator cl i p to posi ti ve (+) battery post.
Connect bl ack (-) al l i gator cl i p to a good ground.
(4) Di sconnect the cool er l i nes at the transmi ssi on.
NOTE: When flushing transmission cooler and
lines, ALWAYS reverse flush.
(5) Connect the BLUE pressure l i ne to the OUT-
LET (From) cool er l i ne.
(6) Connect the CLEAR return l i ne to the I NLET
(To) cool er l i ne
(7) Turn pump ON for two to three mi nutes to
fl ush cool er(s) and l i nes. Moni tor pressure readi ngs
and cl ear return l i nes. Pressure readi ngs shoul d sta-
bi l i ze bel ow 20 psi . for vehi cl es equi pped wi th a si n-
gl e cool er and 30 psi . for vehi cl es equi pped wi th dual
cool ers. I f fl ow i s i ntermi ttent or exceeds these pres-
sures, repl ace cool er.
(8) Turn pump OFF.
(9) Di sconnect CLEAR sucti on l i ne from reservoi r
at cover pl ate. Di sconnect CLEAR return l i ne at
cover pl ate, and pl ace i t i n a drai n pan.
(10) Turn pump ON for 30 seconds to purge fl ush-
i ng sol uti on from cool er and l i nes. Turn pump OFF.
(11) Pl ace CLEAR sucti on l i ne i nto a one quart
contai ner of Mopar ATF Pl us 3 type 7176 automati c
transmi ssi on fl ui d.
(12) Turn pump ON unti l al l transmi ssi on fl ui d i s
removed from the one quart contai ner and l i nes. Thi s
purges any resi dual cl eani ng sol vent from the trans-
mi ssi on cool er and l i nes. Turn pump OFF.
(13) Di sconnect al l i gator cl i ps from battery. Recon-
nect fl usher l i nes to cover pl ate, and remove fl ushi ng
adapters from cool er l i nes.
OIL PUMP VOLUME CHECK
After the new or repai red transmi ssi on has been
i nstal l ed, fi l l to the proper l evel wi th Mopar ATF
PLUS 3 (Type 7176) automati c transmi ssi on fl ui d.
The vol ume shoul d be checked usi ng the fol l owi ng
procedure:
(1) Di sconnect the From cooler l i ne at the trans-
mi ssi on and pl ace a col l ecti ng contai ner under the
di sconnected l i ne.
CAUTION: With the fluid set at the proper level,
fluid collection should not exceed (1) quart or inter-
nal damage to the transmission may occur.
(2) Run the engi ne at curb idle speed, wi th the
shi ft sel ector i n neutral .
(3) I f fl ui d fl ow i s i ntermi ttent or i t takes more
than 20 seconds to col l ect one quart of ATF PLUS 3,
di sconnect the To Cooler l i ne at the transaxl e.
(4) Refi l l the transaxl e to proper l evel and recheck
pump vol ume.
(5) I f fl ow i s found to be wi thi n acceptabl e l i mi ts,
repl ace the cool er. Then fi l l transmi ssi on to the
proper l evel , usi ng Mopar ATF PLUS 3 (Type 7176)
automati c transmi ssi on fl ui d.
(6) I f fl ui d fl ow i s sti l l found to be i nadequate,
check the l i ne pressure usi ng the Transaxl e Hydrau-
l i c Pressure Test procedure.
VEHICLE SPEED SENSOR PINION GEAR
When the sensor i s removed for any reason, a
NEW O-ri ng must be i nstal l ed on i ts outsi de di ame-
ter.
REMOVAL
(1) Remove harness connector from sensor. Make
sure weatherseal stays on harness connector.
(2) Remove bol t securi ng the sensor i n the exten-
si on housi ng.
(3) Careful l y pul l sensor and pi ni on gear assembl y
out of extensi on housi ng.
(4) Remove pi ni on gear from sensor.
INSTALLATION
(1) To i nstal l , reverse the above procedure. Make
sure extensi on housi ng and sensor fl ange are cl ean
pri or to i nstal l ati on. Al ways use a NEW sensor
O-ri ng.
(2) Ti ghten bol t to 7 Nm (60 i n. l bs.). Ti ghten
speedometer cabl e to 4 Nm (35 i n. l bs.).
PARK/NEUTRAL STARTING AND BACK-UP LAMP
SWITCH
TEST
The park/neutral starti ng swi tch i s the center ter-
mi nal of the 3 termi nal swi tch. I t provi des ground for
the starter sol enoi d ci rcui t through the sel ector l ever
i n onl y Park and Neutral posi ti ons.
(1) To test swi tch, remove wi ri ng connector from
swi tch and test for conti nui ty between center pi n of
swi tch and transaxl e case. Conti nui ty shoul d exi st
onl y when transaxl e i s i n Park or Neutral .
(2) Check gearshi ft cabl e adjustment before repl ac-
i ng a swi tch whi ch tests bad.
REMOVAL
(1) Unscrew swi tch from transaxl e case al l owi ng
fl ui d to drai n i nto a contai ner. Move sel ector l ever to
Park, then to Neutral posi ti on, and i nspect to see the
swi tch operati ng l ever fi ngers are centered i n swi tch
openi ng.
INSTALLATION
(1) Screw the swi tch wi th a new seal i nto tran-
saxl e case and ti ghten to 33 Nm (24 ft. l bs.). Retest
swi tch wi th the test l amp.
(2) Add fl ui d to transaxl e to bri ng up to proper
l evel .
(3) The back-up l amp swi tch ci rcui t i s through the
two outsi de termi nal s of the 3 termi nal swi tch.
(4) To test swi tch, remove wi ri ng connector from
swi tch and test for conti nui ty between the two out-
si de pi ns.
(5) Conti nui ty shoul d exi st onl y wi th transaxl e i n
Reverse posi ti on.
(6) No conti nui ty shoul d exi st from ei ther pi n to
the case.
TRANSAXLE AND TORQUE CONVERTER REMOVAL
NOTE: Transaxle removal does NOT require engine
removal.
The transaxl e and torque converter must be
removed as an assembl y; otherwi se, the torque con-
verter dri ve pl ate, pump bushi ng, or oi l seal may be
damaged. The dri ve pl ate wi l l not support a l oad;
therefore, none of the wei ght of the transaxl e shoul d
be al l owed to rest on the pl ate duri ng removal .
REMOVAL
(1) Di sconnect negati ve battery cabl e.
(2) Remove ai r cl eaner and hoses.
(3) Di sconnect throttl e l i nkage and shi ft l i nkage
from transaxl e.
(4) Unpl ug torque converter cl utch connector,
l ocated near the di psti ck. Unpl ug the gear posi ti on
swi tch.
(5) Remove transaxl e di psti ck tube.
(6) Remove the transaxl e cool er l i nes and pl ug.
(7) I nstal l engi ne support fi xture (Fi g. 5) .
(8) Remove bel l housi ng upper bol ts.
(9) Rai se vehi cl e. Remove front wheel s. Refer to
Group 2, Suspensi on to remove or i nstal l wheel hub
nut and both dri ve shafts.
CAUTION: The exhaust flex joint must be discon-
nected from the exhaust manifold anytime the
engine is lowered. If the engine is lowered while the
flex pipe is attached, damage will occur.
(10) Remove bol ts securi ng exhaust fl ex joi nt to
exhaust mani fol d. Di sconnect exhaust pi pe from
mani fol d.
(11) Remove torque converter dust cover. Mark
torque converter and dri ve pl ate wi th chal k, for reas-
sembl y. Rotate engi ne cl ockwi se and remove torque
converter mounti ng bol ts.
(12) Remove engi ne mount bracket from front
crossmember.
(13) Remove front mount i nsul ator through-bol t
and bel l housi ng bol ts.
(14) Posi ti on transaxl e jack (Fi g. 6) .
(15) Remove rear engi ne mount shi el d.
(16) Remove rear engi ne mount bracket bol ts and
bracket.
(17) Remove l eft engi ne mount thru-bol t.
(18) Remove l eft engi ne mount from transaxl e.
(19) Remove starter. Remove l ower bel l housi ng
bol ts.
(20) Careful l y work transaxl e and torque converter
assembl y rearward off engi ne bl ock dowel s and di s-
engage converter hub from end of crankshaft. Attach
a small C clamp to edge of bell housing. This
will hold torque converter in place during tran-
saxle removal. Lower transaxl e and remove assem-
bl y from under the vehi cl e.
(21) To remove torque converter assembl y, remove
Ccl amp from edge of bel l housi ng and sl i de converter
out of transaxl e.
INSTALLATION
(1) When i nstal l i ng transaxl e, reverse the above
procedure.
(2) I f torque converter was removed from transaxl e
be sure to al i gn pump i nner gear pi l ot fl ats wi th
torque converter i mpel l er hub fl ats.
(3) Adjust gearshi ft and throttl e cabl es.
(4) Refi l l transaxl e wi th Mopar ATF PLUS 3
(Automati c Transmi ssi on Fl ui d) Type 7176.
Fig. 5 Engine Support Fixture
Fig. 6 Transaxle Jack
FRONT PUMP OIL SEAL
The pump oi l seal can be repl aced wi thout remov-
i ng the pump and reacti on shaft support assembl y
from the transaxl e case.
REMOVAL
(1) Screw seal remover Tool C-3981-B i nto seal
(Fi g. 7), then ti ghten screw porti on of tool to wi th-
draw the seal .
INSTALLATION
(1) To i nstal l a new seal , pl ace seal i n openi ng of
the pump housi ng (l i p si de faci ng i nward). Usi ng Tool
C-4193 and Handl e Tool C-4171, dri ve new seal i nto
housi ng unti l tool bottoms (Fi g. 8).
TRANSAXLE
Pri or to removi ng any transaxl e parts, pl ug al l
openi ngs and cl ean the uni t, preferabl y wi th steam.
When di sassembl i ng, each part shoul d be washed i n
a sui tabl e sol vent, then dri ed wi th compressed ai r.
Do not wi pe parts wi th shop towel s. Al l mati ng sur-
faces i n the transaxl es are accuratel y machi ned;
therefore, careful handl i ng of al l parts must be exer-
ci sed to avoi d ni cks or burrs.
DISASSEMBLY
Remove al l ol d seal ant before appl yi ng new seal -
ant.
Use onl y Mopar Si l i cone Rubber Seal ant or equi v-
al ent when i nstal l i ng oi l pan.
Put seal ant on the oi l pan fl ange (Fi g. 10) and on
al l oi l pan bol ts (undersi de of bol t head).
Fig. 7 Remove Pump Oil Seal
Fig. 8 Install Pump Oil Seal
Fig. 9 Transaxle Oil Pan Bolts
Fig. 10 Transaxle Oil Pan
Remove neutral starti ng and back-up l amp swi tch.
Measuri ng i nput shaft end pl ay before di sassembl y
wi l l usual l y i ndi cate i f a thrust washer change i s
requi red. The thrust washer i s l ocated between i nput
and output shafts.
Fig. 11 Oil Filter Screws
Fig. 12 Oil Filter
Fig. 13 Remove Parking Rod E-Clip
Fig. 14 Parking Rod
Fig. 15 Valve Body Attaching Bolts
Fig. 16 Valve Body and Governor Tubes
Attach a di al i ndi cator to transaxl e bel l housi ng
wi th i ts pl unger seated agai nst end of i nput shaft
(Fi g. 17).
Move i nput shaft i n and out to obtai n end pl ay
readi ng. End pl ay speci fi cati ons are 0.19 to 1.50 mm
(0.008 to 0.060 i nch).
Record i ndi cator readi ng for reference when reas-
sembl i ng the transaxl e.
Remove Number 6 thrust washer from sun
gear driving shell.
Fig. 17 Measure Input Shaft End Play
Fig. 18 Loosen Lock Nut and Tighten Kickdown
Band Adjusting Screw
Fig. 19 Pump Attaching Bolts
Fig. 20 Install Tool C-3752 with Adapters L-4437
Fig. 21 Oil Pump with No. 1 Thrust Washer
Fig. 22 Oil Pump Gasket
Fig. 23 Loosen Kickdown Band Adjusting Screw
Fig. 24 Kickdown Band and Strut
Fig. 25 Front Clutch Assembly
Fig. 26 No. 2 Thrust Washer and Rear Clutch
Fig. 27 No. 3 Thrust Washer
Fig. 28 Front Planetary Gear Snap Ring
Fig. 29 Front Planetary Gear Assembly
Fig. 30 Sun Gear Driving Shell
Fig. 31 Sun Gear Driving Shell Components
Fig. 33 Rear Planetary Gear Assembly
Fig. 35 Overrunning Clutch Cam Assembly
Fig. 36 Overrunning Clutch Rollers and Spring
Fig. 37 Loosen or Adjust Low/Reverse Band
Fig. 38 Low/Reverse Band and Strut
ASSEMBLY
When rebui l di ng, reverse the above procedure.
VALVE BODY RECONDITION
NOTE: Tighten all valve body screws to 5 Nm (40
in. lbs.).
Do not cl amp any porti on of val ve body or transfer
pl ate i n a vi se. Any sl i ght di storti on of the al umi num
body or transfer pl ate wi l l resul t i n sti cki ng val ves,
excessi ve l eakage or both. When removing or
installing valves or plugs, slide them in or out
carefully. Do not use force.
NOTE: TAG ALL SPRINGS AS THEY ARE
REMOVED FOR REASSEMBLY IDENTIFICATION.
Fig. 40 Install Overrunning Clutch Rollers and
Springs
Fig. 41 Detent Spring Attaching Screw and Spring
Fig. 42 Using Tool L-4553 on Valve Body Screw
Fig. 43 Remove or Install Valve Body Screws
Fig. 44 Transfer Plate and Separator Plate
Fig. 45 Steel Ball Locations
Fig. 46 Remove or Install Throttle Shaft E-Clip
Fig. 47 Throttle Shaft E-Clip, Washer, and Seal
Fig. 48 Manual Valve Lever Assembly
Fig. 49 Throttle Valve Lever Assembly
Fig. 50 Manual Valve
Fig. 52 Pressure Regulators and Manual Controls
Fig. 51 Pressure Regulator and Adjusting Screw
Bracket
Fig. 53 Governor Plugs
Fig. 54 Pressure Regulator Valve Plugs
OIL PUMP-RECONDITION
NOTE: Also, check gear side clearance with a
straight edge and a feeler gauge (See Specifica-
tions).
Fig. 55 Shift Valves and Shuttle Valve
Fig. 56 Reaction Shaft Support Bolts
Fig. 57 Reaction Shaft Support
FRONT CLUTCH-RECONDITION
INSPECTION
I nspect pl ates and di scs for fl atness. They must not
be warped or cone shaped.
I nspect faci ng materi al on al l dri vi ng di scs.
Repl ace di scs that are charred, gl azed or heavi l y pi t-
ted. Di scs shoul d al so be repl aced i f they show evi -
dence of materi al fl aki ng off or i f faci ng materi al can
be scraped off easi l y. I nspect dri vi ng di sc spl i nes for
wear or other damage. I nspect steel pl ate surfaces for
burni ng, scori ng, or damaged dri vi ng l ugs. Repl ace i f
necessary.
I nspect steel pl ate l ug grooves i n cl utch retai ner
for smooth surfaces, pl ates must travel freel y i n
grooves. I nspect band contacti ng surface on cl utch
retai ner for scores, the contact surface shoul d be
protected from damage duri ng di sassembl y and han-
dl i ng. Note bal l check i n cl utch retai ner, make sure
bal l moves freel y. I nspect pi ston seal surfaces i n
cl utch retai ner for ni cks or deep scratches, l i ght
scratches wi l l not i nterfere wi th seal i ng of seal s.
I nspect cl utch retai ner i nner bore surface for wear
from reacti on shaft support seal ri ngs. I nspect
cl utch retai ner bushi ng for wear or scores.
I nspect i nsi de bore of pi ston for score marks, i f
l i ght, remove wi th crocus cl oth. I nspect seal grooves
for ni cks and burrs. I nspect seal s for deteri orati on,
wear, and hardness. I nspect pi ston spri ng, retai ner
and snap ri ng for di storti on.
DISASSEMBLY
Fig. 58 Inner and Outer Pump Gears
Fig. 59 Measuring Pump Clearance (Gear to Pocket)
Fig. 60 Front Clutch Waved Snap Ring
Fig. 61 Thick Steel Plate and Waved Snap Ring
ASSEMBLY
To reassembl e, reverse the above procedure.
MEASURING PLATE CLEARANCE
REAR CLUTCH-RECONDITION
INSPECTION
I nspect faci ng materi al on al l dri vi ng di scs.
Repl ace di scs that are charred, gl azed or heavi l y pi t-
ted. Di scs shoul d al so be repl aced i f they show evi -
dence of materi al fl aki ng off or i f faci ng materi al can
be scraped off easi l y. I nspect dri vi ng di sc spl i nes for
wear or other damage. I nspect steel pl ate and pres-
sure pl ate surface for burni ng, scori ng or damaged
dri vi ng l ugs. Re pl ace i f necessary. I nspect pl ates and
di scs for fl atness, they must not be warped or cone-
shaped.
I nspect steel pl ate l ug grooves i n cl utch retai ner
for smooth surfaces, pl ates must travel freel y i n the
grooves. Note bal l check i n pi ston; make sure bal l
moves freel y. I nspect seal ri ngs surfaces i n cl utch
retai ner for ni cks or deep scratches; l i ght scratches
wi l l not i nterfere wi th seal i ng of the seal s. I nspect
neoprene seal ri ngs for deteri orati on, wear and hard-
ness. I nspect pi ston spri ng and waved snap ri ng for
di storti on or breakage.
I nspect tefl on and/or cast i ron seal ri ngs on i nput
shaft for wear. Do not remove ri ngs unl ess condi ti ons
warrant. I nspect rear cl utch to front cl utch No. 2
thrust washer for wear. Washer thi ckness shoul d be
.061 to .063 i nch, repl ace i f necessary.
DISASSEMBLY
Press out i nput shaft, i f requi red.
ASSEMBLY
To reassembl e, reverse the above procedure.
Fig. 62 Front Clutch (4-Disc Shown)
Fig. 63 Front Clutch Return Spring Snap Ring
Fig. 64 Front Clutch Return Spring and Piston
Fig. 65 Measuring Front Clutch Plate Clearance
Fig. 66 Rear Clutch Outer Snap Ring
Fig. 67 Rear Clutch (4-Disc Shown)
Fig. 68 Piston Spring Waved Snap Ring
Fig. 69 Rear Clutch Piston and Piston Spring
Fig. 70 Remove or Install Input Shaft Snap Ring
Fig. 71 Input Shaft Snap Ring
MEASURING PLATE CLEARANCE
FRONT PLANETARY & ANNULUS GEAR-
RECONDITION
Fig. 72 Measuring Rear Clutch Plate Clearance
Fig. 73 Front Planetary Gear Snap Ring and No. 4
Thrust Washer (Always Install a New Snap Ring)
Fig. 74 Front Planetary Gear
Fig. 75 Annulus Gear Support Front Snap Ring
Fig. 76 Front Annulus Gear Support and Snap Ring
Fig. 77 Front Annulus Gear Support Snap Ring
LOW/REVERSE (REAR) SERVO-RECONDITION
DISASSEMBLY
ASSEMBLY
To assembl e, reverse the above procedure.
ACCUMULATOR-RECONDITION
DISASSEMBLY
Fig. 78 Low/Reverse Lever
Fig. 79 Low/Reverse Servo Snap Ring
Fig. 80 Remove Retainer, Spring and Servo
Fig. 81 Low/Reverse Servo Assembly
Fig. 82 Accumulator Snap Ring
Fig. 83 Accumulator Plate and Snap Ring
ASSEMBLY
KICKDOWN SERVO (CONTROLLED LOAD)-
RECONDITION
DISASSEMBLY
ASSEMBLY
Fig. 84 Accumulator Spring and Piston
Fig. 85 Kickdown Servo Snap Ring
Fig. 86 Kickdown Servo Rod Guide and Snap Ring
Fig. 87 Kickdown Piston Return Spring and Piston
Fig. 88 Controlled Load Kickdown Servo
TRANSFER SHAFT REPAIR
DISASSEMBLY
NOTE: Remove old sealant before applying new
sealant. Use Mopar RTV sealant or equivalent
when installing cover.
NOTE: Remove or install both governor valves and
governor body.
Fig. 89 Rear Cover Bolts
Fig. 90 Remove or Install Rear Cover
Fig. 91 Remove Transfer Shaft Gear Retaining Nut
Fig. 92 Transfer Shaft Gear Nut and Washer
Fig. 93 Remove Transfer Shaft Gear
Fig. 94 Transfer Shaft Gear and (Select) Shim
Fig. 95 Using Tool L-4406-1 with Adapter L-4406-3,
Remove Transfer Shaft Gear Bearing Cone
Fig. 96 Install Transfer Shaft Gear Bearing Cone
Fig. 97 Governor Support Retainer
Fig. 98 Remove Governor Support Retainer Bearing
Cup
Fig. 99 Install Governor Support Retainer Bearing
Cup
Fig. 100 Low-Reverse Band Anchor Pin
Fig. 101 Governor Assembly
Fig. 102 Transfer Shaft Bearing Snap Ring
Fig. 103 Remove Transfer Shaft and Bearing
Retainer Assembly
Fig. 104 Remove or Install Transfer Shaft and
Bearing Retainer Assembly Using Tool L-4512
Fig. 105 Transfer Shaft and Bearing Retainer
Fig. 106 Remove Transfer Shaft Bearing Cone
Fig. 107 Install Transfer Shaft Bearing Cone
Fig. 108 Remove Transfer Shaft Bearing Cup
Fig. 109 Install Transfer Shaft Bearing Cup
DETERMINING SHIM THICKNESS
Shi m thi ckness need onl y be determi ned i f any of
the fol l owi ng parts are repl aced:
Transaxl e case
Transfer shaft
Transfer shaft gear
Transfer shaft beari ngs
Governor support retai ner
Transfer shaft beari ng retai ner
Retai ner snap ri ng
Governor support
Refer to Beari ng Adjustment Procedure i n rear of
thi s secti on to determi ne proper shi m thi ckness.
ASSEMBLY
To i nstal l transfer shaft, reverse the above proce-
dure.
PARKING PAWL
DISASSEMBLY
ASSEMBLY
To i nstal l , reverse the above procedure.
Fig. 110 Tighten Transfer Shaft Gear Retaining Nut
to 271 Nm (200 ft. lbs.)
Fig. 111 Checking Transfer Shaft End Play
Fig. 112 Parking Sprag Rod Support
Fig. 113 Support and Bolts
Fig. 114 Parking Pawl, Return Spring, and Pivot
Shaft
OUTPUT SHAFT REPAIR
NOTE: Transfer shaft should be removed for repair
of output shaft. Planetary gear sets must be
removed to accurately check output shaft bearing
turning torque.
Fig. 115 Remove Output Shaft Retaining Nut and
Washer
Fig. 116 Remove Output Shaft Gear
Fig. 117 Output Shaft Gear and (Select) Shim
Fig. 118 Remove Output Shaft Gear Bearing Cone
Fig. 119 Install Output Shaft Gear Bearing Cone
Fig. 120 Remove Output Shaft and Rear Annulus
Gear Assembly
Fig. 121 Remove Output Shaft
Fig. 122 Remove Rear Planetary Annulus Gear
Bearing Cone
Fig. 123 Install Rear Planetary Annulus Gear
Bearing Cone
Fig. 124 Install Output Shaft into Rear Planetary
Annulus Gear
Fig. 125 Remove Output Shaft Gear Bearing Cup
Fig. 126 Remove Rear Planetary Annulus Gear
Bearing Cup
Shi m thi ckness need onl y be determi ned i f any of
Transaxl e case
Output shaft
Rear pl anetary annul us gear
Output shaft gear
Rear annul us and output shaft gear beari ng
cones
Overrunni ng cl utch race cups
Refer to Beari ng Adjustment Procedure at the rear
of thi s secti on, to determi ne proper shi m thi ckness.
Check output shaft bearings turning torque,
using an inch-pound torque wrench. If turning
torque is 3 to 8 inch-pounds, the proper shim
has been installed.
Fig. 127 Install Output Shaft Gear Bearing Cup
Fig. 128 Install Rear Planetary Annulus Gear
Bearing Cup
Fig. 129 Install Output Shaft Assembly
Fig. 130 Output Shaft and (Select) Shims in Position
Fig. 131 Start Output Shaft Gear onto Output Shaft
Fig. 132 Holding Output Shaft Gear
DIFFERENTIAL REPAIR
NOTE: The transfer shaft should be removed for
differential repair and bearing turning torque check-
ing.
Fig. 133 Tighten Output Shaft Retaining Nut to 271
Nm (200 ft. lbs.)
Fig. 134 Checking Output Shaft End Play
Fig. 135 Checking Bearings Turning Torque
Fig. 136 Remove Extension Seal
Fig. 137 Install New Seal into Extension
Fig. 138 Differential Cover Bolts
NOTE: Use Mopar RTV sealant, or equivalent,
when installing differential cover.
Fig. 139 Remove or Install Differential Cover
Fig. 140 Remove Bearing Retainer Axle Seal
Fig. 141 Install Bearing Retainer Axle Seal
Fig. 142 Differential Bearing Retainer Bolts
Fig. 143 Remove or Install Bearing Retainer
Fig. 144 Differential Bearing Retainer (Typical)
NOTE: Use Mopar RTV sealant, or equivalent,
when installing differential bearing retainer.
WARNING: HOLD ONTO DIFFERENTIAL ASSEMBLY
TO PREVENT IT FROM ROLLING OUT OF HOUSING.
Use Mopar Si l i cone Rubber Adhesi ve Seal ant, or
equi val ent, when i nstal l i ng extensi on housi ng.
Fig. 145 Extension Bolts
Fig. 146 Remove or Install Extension Housing
Fig. 147 Differential and Extension
Fig. 148 Remove Differential Bearing Cone
(Extension Housing Side)
Fig. 149 Position Bearing Cone Onto Differential
Fig. 150 Install Differential Bearing Cone
To i nstal l the di fferenti al beari ng cup and cone on
the ri ng gear si de, use Speci al Tool 5052, and Speci al
Tool C-4171.
NOTE: The differential is serviced as an assembly.
The only parts that are serviceable within the differ-
ential are the differential bearing cups and cones. If
any other part fails within the differential, you must
replace the differential assembly along with the
transfer shaft.
CAUTION: Side gear end play must be BETWEEN
0.001 to 0.013 inch.
Fig. 151 Position Button and Collets Onto
Differential and Bearing (Ring Gear Side)
Fig. 152 Position Tool 5048 Over Button and Collets
at Differential Bearing
Fig. 154 Checking Side Gear End Play
Fig. 155 Checking Side Gear End Play (Typical)
To remove the di fferenti al beari ng cup from the
extensi on housi ng/adapter si de, use Speci al Tool
6062A, Remover. To i nstal l the di fferenti al beari ng
cup on the extensi on housi ng/adapter si de, use Spe-
ci al Tool 6536, Dri ver and Speci al Tool C-4171, Han-
dl e.
Shi m thi ckness need be determi ned onl y i f any of
Transaxl e case
Di fferenti al carri er
Di fferenti al beari ng retai ner
Extensi on housi ng
Di fferenti al beari ng cups and cones
Refer to Beari ng Adjustment Procedure i n rear of
thi s secti on to determi ne proper shi m thi ckness.
VALVE BODY
Al l ow al l parts to soak a few mi nutes i n a sui tabl e
cl ean sol vent. Wash thoroughl y and bl ow dry wi th
compressed ai r. Make sure al l passages are cl ean and
free from obstructi ons.
I nspect manual and throttl e val ve operati ng l evers
and shafts for bei ng bent, worn or l oose. I f a l ever i s
l oose on i ts shaft, i t shoul d be repl aced. Do not
attempt to strai ghten bent l evers.
I nspect al l mati ng surfaces for burrs, ni cks and
scratches. Mi nor bl emi shes may be removed wi th cro-
cus cl oth, usi ng onl y a very l i ght pressure. Usi ng a
strai ghtedge, i nspect al l mati ng surfaces for warpage
or di storti on. Sl i ght di storti on may be corrected,
usi ng a surface pl ate. Make sure al l meteri ng hol es
i n steel pl ate are open. Usi ng a pen l i ght, i nspect
bores i n val ve body for scores, scratches, pi ts and
i rregul ari ti es.
Fig. 156 Differential Bearing Retainer
Fig. 157 Position Bearing Cup Remover Tool in
Retainer
Fig. 158 Remove Bearing Cup
Fig. 159 Install Bearing Cup
I nspect al l val ve spri ngs for di storti on and col -
l apsed coi l s. I nspect al l val ves and pl ugs for burrs,
ni cks, and scores. Smal l ni cks and scores may be
removed wi th crocus cl oth, provi di ng extreme care i s
taken not to round off sharp edges. The sharpness of
these edges i s vi tal l y i mportant. I t prevents forei gn
matter from l odgi ng between val ve and val ve body.
Thi s reduces the possi bi l i ty of sti cki ng. I nspect al l
val ves and pl ugs for freedom of operati on i n val ve
body bores.
When bores, val ves, and pl ugs are cl ean and dry,
the val ves and pl ugs shoul d fal l freel y i n the bores.
The val ve body bores do not change i ts di mensi ons
wi th use. Therefore, a val ve body that was functi on-
i ng properl y when vehi cl e was new, wi l l operate cor-
rectl y i f i t i s properl y and thoroughl y cl eaned. There
i s no need to repl ace val ve body unl ess i t i s damaged
i n handl i ng.
ADJ USTMENTS
GEARSHIFT CABLE ADJUSTMENT
Li ft and rotate the gearshi ft hand l ever i nto the
park (P) gate posi ti on and remove the i gni ti on key.
Thi s confi rms the shi ft l ever i s i n the gated park (P)
posi ti on.
After confi rmi ng the park gate posi ti on, turn the
i gni ti on swi tch. I f the starter wi l l operate, the park
gate posi ti on i s correct. Move the shi ft l ever i nto the
neutral (N) posi ti on. I f the starter wi l l operate i n thi s
posi ti on, the l i nkage i s properl y adjusted. I f the
starter fai l s to operate i n ei ther posi ti on, l i nkage
adjustment i s requi red.
(1) Park the vehi cl e on l evel ground and set the
parki ng brake.
(2) Pl ace the gearshi ft l ever i n park (P) gate posi -
ti on and remove key.
(3) Loosen the cabl e adjustment screw at the tran-
saxl e operati ng l ever (Fi g. 160).
(4) Pul l the transaxl e operati ng l ever ful l y forward
to the park detent posi ti on.
(5) Rel ease the park brake, then rock the vehi cl e
to assure i t i s i n park l ock. Reset the park brake.
(6) Ti ghten the cabl e adjustment screw to 8 Nm
(70 i n. l bs.). Gearshi ft cabl e shoul d now be properl y
adjusted.
(7) Veri fy PRNDL i ndi cator sti l l di spl ays the corre-
spondi ng gear compl etel y. I f not, readjustment of
PRNDL may be requi red.
(8) Check adjustment by usi ng the precedi ng pro-
cedure.
THROTTLE PRESSURE LINKAGE ADJUSTMENT
The throttl e pressure rod adjustment i s very
i mportant to proper transaxl e operati on. Thi s adjust-
ment posi ti ons a val ve whi ch control s shi ft speed,
shi ft qual i ty, and part throttl e downshi ft sensi ti vi ty.
I f the setti ng i s too short, earl y shi fts and sl i ppage
between shi fts may occur. I f the setti ng i s too l ong,
shi fts may be del ayed and part throttl e downshi fts
may be very sensi ti ve.
Wi th engi ne at operati ng temperature, adjust i dl e
speed of engi ne usi ng a tachometer. Refer to Group
14, Fuel System for i dl e speed Speci fi cati ons and
adjustment.
ROD ADJ USTMENT PROCEDURE
(1) Perform transaxl e throttl e pressure adjustment
whi l e engi ne i s at normal operati ng temperature.
(2) Loosen adjustment swi vel l ock screw.
(3) To i nsure proper adjustment, swi vel must be
free to sl i de al ong fl at end of throttl e rod. Di sassem-
bl e and cl ean or repai r parts to assure free acti on, i f
necessary.
(4) Hol d transaxl e throttl e l ever fi rml y toward
engi ne, agai nst i ts i nternal stop. Ti ghten swi vel l ock
screw to 11 Nm (100 i n. l bs.)
(5) The adjustment i s fi ni shed and l i nkage back-
l ash was automati cal l y removed by the prel oad
spri ng.
(6) I f l ubri cati on i s requi red see Group 0, Lubri ca-
ti on.
BAND ADJUSTMENT
KICKDOWN BAND (FRONT)
The ki ckdown band adjusti ng screw i s l ocated on
l eft si de (top front) of the transaxl e case.
(1) Loosen l ocknut and back off nut approxi matel y
fi ve turns. Test adjusti ng screw for free turni ng i n
the transaxl e case.
(2) Usi ng wrench, ti ghten adjusti ng screw to 8
Nm (72 i n. l bs.).
Fig. 160 Gearshift Cable Adjustment
(3) Back off adjusti ng screw the number of turns
l i sted i n Speci fi cati ons. Hol d adjusti ng screw i n thi s
posi ti on and ti ghten l ocknut to 47 Nm (35ft. l bs.)
LOW/REVERSE BAND (REAR)
To adjust l ow-reverse band, proceed as fol l ows:
(1) Loosen and back off l ocknut approxi matel y 5
turns.
(2) Usi ng an i nch-pound torque wrench, ti ghten
adjusti ng screw to 5 Nm (41 i n. l bs.) true torque.
(3) Back off adjusti ng screw the number of turns
l i sted under Speci fi cati ons. Thi s chart i s l ocated at
the rear of thi s secti on.
HYDRAULIC CONTROL PRESSURE ADJUSTMENTS
LINE PRESSURE
An i ncorrect throttl e pressure setti ng wi l l cause
i ncorrect l i ne pressure readi ngs even though l i ne
pressure adjustment i s correct. Al ways i nspect and
correct throttl e pressure adjustment before adjusti ng
the l i ne pressure.
The approxi mate adjustment for l i ne pressure i s
1-5/16 i nches, measured from val ve body to i nner
edge of adjusti ng nut. However, due to manufactur-
i ng tol erances, the adjustment can be vari ed to
obtai n speci fi ed l i ne pressure.
The adjusti ng screw may be turned wi th an Al l en
wrench. One compl ete turn of adjusti ng screw
changes cl osed throttl e l i ne pressure approxi matel y
1-2/3 psi . Turni ng adjusti ng screw countercl ockwi se
i ncreases pressure, and cl ockwi se decreases pressure.
THROTTLE PRESSURE
Throttl e pressures cannot be tested accuratel y;
therefore, the adjustment shoul d be measured i f a
mal functi on i s evi dent.
(1) I nsert gauge pi n of Tool C-3763 between the
throttl e l ever cam and ki ckdown val ve.
(2) By pushi ng i n on tool , compress ki ckdown
val ve agai nst i ts spri ng so throttl e val ve i s com-
pl etel y bottomed i nsi de the val ve body.
(3) Whi l e compressi ng spri ng, turn throttl e l ever
stop screw wi th adapter C-4553. Turn unti l head of
screw touches throttl e l ever tang, wi th throttl e l ever
cam touchi ng tool and throttl e val ve bottomed. Be
sure adjustment i s made wi th spri ng ful l y com-
pressed and val ve bottomed i n the val ve body.
BEARING ADJUSTMENT PROCEDURES
(1) Take extreme care when removi ng and i nstal l -
i ng beari ng cups and cones. Use only an arbor
press for installation, as a hammer may not
properly align the bearing cup or cone. Burrs or
ni cks on the beari ng seat wi l l gi ve a fal se end pl ay
readi ng, whi l e gaugi ng for proper shi ms. I mproperl y
seated beari ng cup and cones are subject to l ow-mi l e-
age fai l ure.
(2) Beari ng cups and cones shoul d be repl aced i f
they show si gns of pi tti ng or heat di stress.
(3) I f di stress i s seen on ei ther the cup or beari ng
rol l ers, both cup and cone must be repl aced.
NOTE: Bearing end play and drag torque specifica-
tions must be maintained to avoid premature bear-
ing failures.
(4) Used (ori gi nal ) beari ng may l ose up to 50 per-
cent of the ori gi nal drag torque after break-i n.
NOTE: All bearing adjustments must be made with
no other component interference or gear inter-
mesh, except the transfer gear bearing.
(5) Refer to the conversi on chart i n speci fi cati ons
to convert i nches to mi l l i meter measurements. Refer
to beari ng shi m chart for proper shi m thi cknesses.
OUTPUT SHAFT BEARING
(1) Wi th output shaft gear removed, i nstal l a 13.65
mm (.537 i nch) and a 1.34 mm (.053 i nch) gaugi ng
shi ms on the pl anetary rear annul us gear hub usi ng
grease to hol d the shi ms i n pl ace. The 13.65 mm
shi m has a l arger i nsi de di ameter and must be
i nstal l ed over the output shaft fi rst. The 1.34 mm
shi m pi l ots on the output shaft.
(2) I nstal l output shaft gear and beari ng assembl y,
torque to 271 Nm (200 ft. l bs.).
(3) To measure beari ng end pl ay:
(4) Attach Tool L-4432 to the output shaft gear.
(5) Mount a steel bal l wi th grease i nto the end of
the output shaft.
(6) Push and pul l the gear whi l e rotati ng back and
forth to i nsure seati ng of the beari ng rol l ers.
(7) Usi ng a di al i ndi cator, mounted to the tran-
saxl e case, measure output shaft end pl ay.
(8) Once beari ng end pl ay has been determi ned,
refer to the output shaft beari ng shi m chart.
(9) The 12.65 mm (.498 i nch), 13.15 mm (.518
i nch) or 13.65 mm (.537 i nch) shi ms are al ways
i nstal l ed fi rst. These shims have lubrication slots
which are necessary for proper bearing lubrica-
tion.
(10) Shi ms thi nner than 12.65 mm l i sted i n the
chart are common to both the transfer shaft and out-
put shaft beari ngs.
(11) Use Tool L-4434 to remove the retai ni ng nut
and washer. To remove the output shaft gear use Tool
L-4407.
(12) Remove the two gaugi ng shi ms and i nstal l the
proper shi m combi nati on, maki ng sure to i nstal l the
12.65, 13.15, or 13.65 mm shi m fi rst. Use grease to
hol d the shi ms i n pl ace. I nstal l the output shaft gear
(13) I nstal l the retai ni ng nut and washer and
torque to 271 Nm (200 ft. l bs.).
(14) Usi ng an i nch-pound torque wrench, check the
turni ng torque. The torque should be between 3
and 8 inch-pounds.
(15) I f the turni ng torque i s too hi gh, i nstal l a
.05mm (.002 i nch) thi cker shi m. I f the turni ng torque
i s too l ow, i nstal l a .05 mm (.002 i nch) thi nner shi m.
Repeat unti l the proper turni ng torque i s 3 to 8 i nch
pounds.
DIFFERENTIAL BEARING
(1) Posi ti on the transaxl e assembl y verti cal l y on
the support stand, di fferenti al beari ng retai ner si de
up.
(2) I nstal l Tool L-4436A i nto the di fferenti al and
onto the pi ni on mate shaft .
(3) Rotate the di fferenti al at l east one ful l revol u-
ti on to ensure the tapered rol l er beari ngs are ful l y
seated.
(4) Usi ng Tool L-4436A and an i nch-pound torque
wrench, check the turni ng torque of the di fferenti al .
The turning torque should be between 5 and 18
inch-pounds.
(5) I f the turni ng torque i s wi thi n speci fi cati ons,
remove tool s. Setup i s compl ete.
(6) I f turni ng torque i s not wi thi n speci fi cati ons
proceed wi th the fol l owi ng steps.
(a) Remove di fferenti al beari ng retai ner from
(b) Remove the beari ng cup from the di fferenti al
beari ng retai ner usi ng Tool 6062A.
(c) Remove the exi sti ng shi m from under the
cup.
(d) Measure the exi sti ng shi m.
OUTPUT SHAFT BEARING SHIM CHART
Fig. 161 Tool L-4436 and Torque Wrench
Fig. 162 Checking Differential Bearings Turning
Torque
NOTE: If the turning torque was too high when
measured, install a .05 mm (.002 inch) thinner shim.
If the turning torque is was too low, install a .05 mm
(.002 inch) thicker shim. Repeat until 5 to 18 inch-
pounds turning torque is obtained.
Oil Baffle is not required when making shim
selection.
(e) I nstal l the proper shi m under the beari ng
cup. Make sure the oi l baffl e i s i nstal l ed properl y
i n the beari ng retai ner, bel ow the beari ng shi m
and cup.
(f) I nstal l the di fferenti al beari ng retai ner usi ng
Tool 5052 and C-4171. Seal the retai ner to the
housi ng wi th MOPAR Adhesi ve Seal ant and
torque bol ts to 28 Nm (250 i n. l bs.).
wrench, recheck the turni ng torque of the di fferen-
ti al . The turning torque should be between 5
and 18 inch-pounds.
TRANSFER SHAFT BEARING
and washer. Remove the transfer shaft gear usi ng
Tool L-4407.
(2) I nstal l a 2.29 mm (.090 i nch) and a 1.39 mm
(.055 i nch) gaugi ng shi ms on the transfer shaft
behi nd the governor support.
(3) I nstal l transfer shaft gear and beari ng assem-
bl y and torque the nut to 271 Nm (200 ft. l bs.).
(4) To measure beari ng end pl ay:
(5) Attach Tool L-4432 to the transfer gear.
(6) Mount a steel bal l wi th grease i nto the end of
the transfer shaft.
(8) Usi ng a di al i ndi cator, measure transfer shaft
end pl ay.
(9) Refer to the Transfer Beari ng Shi m Chart for
the requi red shi m combi nati on to obtai n the proper
beari ng setti ng.
and washer. Remove the transfer shaft gear usi ng
Tool L-4407.
(11) Remove the two gaugi ng shi ms and i nstal l the
correct shi m combi nati on. I nstal l the transfer gear
(12) I nstal l the retai ni ng nut and washer and
torque to 271 Nm (200 ft. l bs.). Measure transfer
shaft end pl ay, end pl ay shoul d be .05 to .25 mm
(.002 to .010 i nch).
(13) Measure beari ng end pl ay as outl i ned i n Step
(4). End pl ay shoul d be between .05 mm and .25 mm
(.002 to .010 i nch).
DIFFERENTIAL BEARING SHIM CHART
SHIM THICKNESS
MM INCH
.980 0.0386
1.02 0.0402
1.06 0.0418
1.10 0.0434
1.14 0.0449
1.18 0.0465
1.22 0.0481
1.26 0.0497
1.30 0.0512
1.34 0.0528
1.38 0.0544
1.42 0.0560
1.46 0.0575
1.50 0.0591
1.54 0.0607
1.58 0.0623
1.62 0.0638
1.66 0.0654
1.70 0.0670
2.02 0.0796
2.06 0.0812
NOTE: If end play is too high, install a .05 mm (.002
inch) thinner shim combination. If end play is too
low, install a .05 mm (.002 inch) thicker shim com-
bination. Repeat until .05 to .25 mm (.002 to .010
inch) end play is obtained.
TRANSFER BEARING SHIM CHART
31TH TRANSAXLE HYDRAULIC SCHEMATIC
3
1
T
H
T
R
A
N
S
A
X
L
E
H
Y
D
R
A
U
L
I
C
S
C
H
E
M
A
T
I
C
3
1
T
H
T
R
A
N
S
A
X
L
E
H
Y
D
R
A
U
L
I
C
S
C
H
E
M
A
T
I
C
SCHEMATICS AND DIAGRAMS (Continued)
3
1
T
H
T
R
A
N
S
A
X
L
E
H
Y
D
R
A
U
L
I
C
S
C
H
E
M
A
T
I
C
3
1
T
H
T
R
A
N
S
A
X
L
E
H
Y
D
R
A
U
L
I
C
S
C
H
E
M
A
T
I
C
3
1
T
H
T
R
A
N
S
A
X
L
E
H
Y
D
R
A
U
L
I
C
S
C
H
E
M
A
T
I
C
3
1
T
H
T
R
A
N
S
A
X
L
E
H
Y
D
R
A
U
L
I
C
S
C
H
E
M
A
T
I
C
3
1
T
H
T
R
A
N
S
A
X
L
E
H
Y
D
R
A
U
L
I
C
S
C
H
E
M
A
T
I
C
3
1
T
H
T
R
A
N
S
A
X
L
E
H
Y
D
R
A
U
L
I
C
S
C
H
E
M
A
T
I
C
SPECIFICATIONS
Type . . . . . . . . . . . . . . . .Automati c three speed wi th
torque converter and i ntegral di fferenti al
Torque Converter Di ameter . . . . . . . .241 mi l l i meters
(9.48 i n.)
Oi l Capaci ty . . . . . . . . . . . . . .8.6 Li ters (18.25 pi nts)
Oi l Type . . . . . . . . . .Mopar ATF PLUS 3 Type 7176
Cool i ng Method . . . . . .Water Heat Exchanger and/or
ai r to oi l heat exchanger
Lubri cati on . . . . . .Pump (i nternal -external gear-type
Gear Ratios
Transmission Portion
Fi rst Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.69
Second Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.55
Thi rd Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.00
Reverse Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.10
Pump Clearances
Outer Gear To Pocket . . . . . . . . . . . . .0.045-0.141mm
(0.0018-0.0056 i n.)
Outer Gear Si de Cl earance. . . . . . . . .0.020-0.046mm
(0.0008-0.0018 i n.)
I nner Gear Si de Cl earance . . . . . . . . .0.020-0.046mm
(0.0008-0.0018 i n.)
Tapered Roller Bearing Settings
Di fferenti al Assembl y . . .6 to 12 i n. l bs. Drag Torque
Output Hub. . . . . . . . . . . .0 to 3 i n. l bs. Drag Torque
Transfer Shaft . . . . . . . . .0.002 to 0.010 i n. End Pl ay
Overal l Drag At Output
Hub . . . . . . . . . . . . .3 to 16 i n. l bs. Drag Torque
Clutch Pack Clearances
Front Cl utch (Not Adjustabl e) . . . . . . . .1.27-2.79mm
(0.050-0.110 i n.)
Rear Cl utch . . . . . . . . .0.71-1.10mm (0.028-0.043 i n.)
Band Adjustment
Ki ckdown, Backed Off From 8 Nm
(72 i n. l bs.) . . . . . . . . . . . . . . . . . . . . . 2 1/4 Turns
Low-Reverse, Backed Off From 5 Nm
(41 i n. l bs.) . . . . . . . . . . . . . . . . . . . . . .3 1/2 Turns
31TH TORQUE SPECIFICATIONS
DESCRIPTION TORQUE DESCRIPTION TORQUE
Bell Housing Cover Bolts 12 Nm (106 in. lbs.) Output Shaft Nut 271 Nm (200 ft. lbs.)
Cooler Hose To Rad. Conn. 12 Nm (105 in. lbs.) Park/Neutral Switch 34 Nm (25 ft. lbs.)
Cooler Line Conn. 28 Nm (250 in. lbs.) Pressure Check Plug 5 Nm (45 in. lbs.)
Diff. Bear. Ret. To Case Bolt 28 Nm (250 in. lbs.) Pump To Case Bolts 31 Nm (275 in. lbs.)
Diff. Cover To Case Bolt 19 Nm (165 in. lbs.) Reaction Shaft Assembly Bolt 28 Nm (250 in. lbs.)
Exten. Hous. To Case Bolt 28 Nm (250 in. lbs.) Rear Cover To Case Screw 19 Nm (165 in. lbs.)
Flex Plate To Crankshaft Bolts 95 Nm (70 ft. lbs.) Reverse Band Adj. Lock Nut 14 Nm (125 in. lbs.)
Flex Plate To Torque Conv. Bolts 68 Nm (50 ft. lbs.) Reverse Band Shaft Plug 7 Nm (60 in. lbs.)
Fluid Filter Screw 5 Nm (45 in. lbs.) Ring Gear Screw 95 Nm (70 ft. lbs.)
Front Motor Mount Bolt 54 Nm (40 ft. lbs.) Speedo. To Ext. Hous. Screw 7 Nm (60 in. lbs.)
Governor Counterweight Screw 28 Nm (250 in. lbs.) Sprag Ret. To Transfer Case Bolt 28 Nm (250 in. lbs.)
Governor To Support Bolt 7 Nm (60 in. lbs.) Starter To Trans. Bell Bolts 54 Nm (40 ft. lbs.)
Kickdown Band Adj. Lock Nut 47 Nm (35 ft. lbs.) Throttle Cable To Trans. Case
Bolt
12 Nm (105 in. lbs.)
Left Motor Mount Bolts 54 Nm (40 ft. lbs.) Throttle Lever To Trans. Shaft
Bolts
12 Nm (105 in. lbs.)
Lower Bell Housing Cover Screw 41 Nm (30 ft. lbs.) Trans. To Cyl. Block Bolt 95 Nm (70 ft. lbs.)
Manual Cable To Trans. Case Bolt 28 Nm (250 in. lbs.) Transfer Shaft Nut 271 Nm (200 ft. lbs.)
Manual Control Lever Screw 12 Nm (105 i n. lbs.) Transfer Gear Strap Bolts 23 Nm (17 ft. lbs.)
Oil Pan To Trans. Case Screw 19 Nm (165 in. lbs.) Valve Body Assy. To Case Bolts 12 Nm (105 in. lbs.)
Output Gear Strap Bolts 23 Nm (17 ft. lbs.) Valve Body Screw 5 Nm (45 in. lbs.)
SPECIAL TOOLS
Adapter Blocks C-29345
Adapter Blocks C-29352
Puller Press C-293PA
Pressure Gauge (Low) C-3292
Pressure Gauge (High) C-3293SP
Spring Compressor C-3575A
Band Adjusting Adapter
Oil Pump Puller C-3752
Throttle Setting Gauge
Seal Puller C-3981B
Universal Handle C-4171
Seal Installer C-4193A
Bearing Installer C-4637
Adapter C-4658
Torque Tool C-4995
Adapter C-4996
Remover Kit L-4406
Bearing Remover Cup L-44061
Bearing Remover Jaws L-44062
Adapter L-44063
Gear Puller L-4407A
Puller L-44076
Bearing Installer L-4408
Installer Adapter L-4429-3
Gear Checking Plate L-4432
Gear Removing Plate L-4434
Bearing Puller L-4435
Differential Tool L-4436A
Housing Remover Adapter L-4437
Starter Nut L-4439
Transfer Shaft Remover-Installer L-4512
Bearing Cup Remover L-4517
Special Jaw Set L-4518
Installer L-4520
Bearing Splitter P-334
Cooling System Tester 7700
41TE AUTOMATIC TRANSAXLE
INDEX
page page
GENERAL INFORMATION
41TE FOUR SPEED AUTOMATIC TRANSAXLE . 71
FLUID LEVEL AND CONDITION . . . . . . . . . . . . . 72
SELECTION OF LUBRICANT . . . . . . . . . . . . . . . 72
SPECIAL ADDITIVES . . . . . . . . . . . . . . . . . . . . . 72
ADAPTIVE CONTROLS . . . . . . . . . . . . . . . . . . . 73
CLUTCH AND GEAR . . . . . . . . . . . . . . . . . . . . . 72
ELECTRONICS . . . . . . . . . . . . . . . . . . . . . . . . . 73
GEARSHIFT AND PARKING LOCK CONTROLS . 74
HYDRAULICS . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
ON-BOARD DIAGNOSTICS . . . . . . . . . . . . . . . . 74
SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
SHIFT POSITION INDICATOR . . . . . . . . . . . . . . 74
SOLENOIDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
TORQUE MANAGEMENT . . . . . . . . . . . . . . . . . . 74
TRANSMISSION CONTROL MODULE . . . . . . . . 74
TRANSMISSION RANGE SENSOR . . . . . . . . . . . 74
41TE TRANSAXLE GENERAL DIAGNOSIS . . . . . 75
CLUTCH AIR PRESSURE TESTS . . . . . . . . . . . . 77
FLUID LEAKAGE-TORQUE CONVERTER
HOUSING AREA . . . . . . . . . . . . . . . . . . . . . . . 78
HYDRAULIC PRESSURE TESTS . . . . . . . . . . . . 75
ROAD TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
SHIFT POSITION INDICATOR . . . . . . . . . . . . . . 78
SERVICE PROCEDURES
ALUMINUM THREAD REPAIR . . . . . . . . . . . . . . 81
FLUID AND FILTER CHANGE . . . . . . . . . . . . . . . 79
FLUID DRAIN AND REFILL . . . . . . . . . . . . . . . . . 81
FLUSHING COOLERS AND TUBES . . . . . . . . . . 81
OIL PUMP VOLUME CHECK . . . . . . . . . . . . . . . 82
PINION FACTOR PROCEDURE . . . . . . . . . . . . . 83
TRANSAXLE QUICK LEARN PROCEDURE . . . . 82
GEARSHIFT CABLE . . . . . . . . . . . . . . . . . . . . . . 83
MANUAL VALVE LEVER (SHIFT LEVER) . . . . . . 84
OIL PUMP SEAL . . . . . . . . . . . . . . . . . . . . . . . . . 92
SOLENOID ASSEMBLY-REPLACE . . . . . . . . . . . 85
SPEED SENSOR-INPUT . . . . . . . . . . . . . . . . . . . 86
SPEED SENSOR-OUTPUT . . . . . . . . . . . . . . . . . 86
TRANSAXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
TRANSMISSION CONTROL MODULE . . . . . . . . 87
TRANSMISSION RANGE SENSOR . . . . . . . . . . . 85
VALVE BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
DIFFERENTIAL REPAIR . . . . . . . . . . . . . . . . . . 139
INPUT CLUTCHES-RECONDITION . . . . . . . . . . 110
TRANSAXLE ASSEMBLE . . . . . . . . . . . . . . . . . 122
TRANSAXLE DISASSEMBLE . . . . . . . . . . . . . . . 95
VALVE BODY RECONDITION . . . . . . . . . . . . . . . 92
CLEANING VALVE BODY . . . . . . . . . . . . . . . . . 144
ADJUSTMENTS
GEARSHIFT CABLE ADJUSTMENT . . . . . . . . . 144
41TE TRANSAXLE HYDRAULIC SCHEMATICS . 145
SPECIFICATIONS
41TE AUTOMATIC TRANSAXLE . . . . . . . . . . . . 158
41TE TORQUE SPECIFICATIONS . . . . . . . . . . 158
SPECIAL TOOLS
41TE AUTOMATIC TRANSAXLE . . . . . . . . . . . . 159
GENERAL INFORMATION
41TE FOUR SPEED AUTOMATIC TRANSAXLE
The 41TE four-speed FWD transaxl e uses ful l y-
adapti ve control s. Adapti ve control s are those whi ch
perform thei r functi ons based on real -ti me feedback
sensor i nformati on. The transaxl e uses hydraul i cal l y
appl i ed cl utches to shi ft a pl anetary gear trai n.
TRANSAXLE IDENTIFICATION
The 41TE transaxl e i denti fi cati on code i s pri nted
on a l abel . The l abel i s l ocated on the transaxl e case
next to the sol enoi d assembl y (Fi g. 1).
Fig. 1 Identification Tag Location
OPERATION
The gear rati os for the 41TE transaxl e are as fol -
l ows:
1st2.84
2nd1.57
3rd1.00
OD0.69
Reverse2.21
Fi nal Dri ve Rati o i s dependent on whi ch engi ne
opti on i s sel ected.
2.4 Li ter: 3.91 FDR
The torque converter cl utch i s avai l abl e i n 2nd,
di rect, or overdri ve gear;. The shi ft l ever i s conven-
ti onal wi th si x posi ti ons: P, R, N, OD, 3, and L avai l -
abl e. When OD i s sel ected the transaxl e shi fts
through al l four speeds wi th torque converter cl utch
avai l abl e i n overdri ve. Thi s posi ti on i s recommended
for most dri vi ng. The 3 posi ti on i s tai l ored for use i n
hi l l y or mountai nous dri vi ng. When 3 i s sel ected, the
transmi ssi on uses onl y 1st, 2nd, and di rect gears
wi th 2nd-di rect shi ft del ayed to 40 mph or greater.
When operati ng i n 3 or L posi ti ons torque converter
cl utch appl i cati on occurs i n di rect gear. Thi s
i mproves transmi ssi on cool i ng under heavy l oads. I f
hi gh engi ne cool ant temperature occurs, the torque
converter cl utch wi l l al so engage i n 2nd gear. The L
posi ti on provi des maxi mum engi ne braki ng for
descendi ng steep grades. Unl i ke most current tran-
saxl es, upshi fts are provi ded to 2nd or di rect gear at
peak engi ne speeds i f the accel erator i s depressed.
Thi s provi des engi ne over-speed protecti on and max-
i mum performance.
FLUID LEVEL AND CONDITION
NOTE: The transmission and differential sump have
a common oil sump with an opening between the
two.
The torque converter fi l l s i n both the (P) Park and
(N) Neutral posi ti ons. Pl ace the sel ector l ever i n (P)
Park to check the fl ui d l evel . The engine should be
running at idle speed for at least one minute,
with the vehicle on level ground. This will
assure complete oil level stabilization between
differential and transmission. The fl ui d shoul d be
at normal operati ng temperature (approxi matel y 82
C. or 180 F.). The fl ui d l evel i s correct i f i t i s i n the
HOT regi on (cross-hatched area) on the oi l l evel i ndi -
cator.
Low fl ui d l evel can cause a vari ety of condi ti ons
because i t al l ows the pump to take i n ai r al ong wi th
the fl ui d. As i n any hydraul i c system, ai r bubbl es
make the fl ui d spongy, therefore, pressures wi l l be
l ow and bui l d up sl owl y.
I mproper fi l l i ng can al so rai se the fl ui d l evel too
hi gh. When the transaxl e has too much fl ui d, the
gears churn up foam and cause the same condi ti ons
whi ch occur wi th a l ow fl ui d l evel .
I n ei ther case, the ai r bubbl es can cause overheat-
i ng, fl ui d oxi dati on, and varni shi ng. Thi s can i nter-
fere wi th normal val ve, cl utch, and accumul ator
operati on. Foami ng can al so resul t i n fl ui d escapi ng
from the transaxl e vent where i t may be mi staken
for a l eak.
Al ong wi th fl ui d l evel , i t i s i mportant to check the
condi ti on of the fl ui d. When the fl ui d smel l s burned,
and i s contami nated wi th metal or fri cti on materi al
parti cl es, a compl ete transaxl e overhaul i s needed.
Be sure to exami ne the fl ui d on the di psti ck cl osel y.
I f there i s any doubt about i ts condi ti on, drai n out a
sampl e for a doubl e check.
After the fl ui d has been checked, seat the di psti ck
ful l y to seal out water and di rt.
I t i s i mportant that the proper l ubri cant be used i n
the 41TE transaxl e. MOPAR ATF PLUS 3 (Auto-
mati c Transmi ssi on Fl ui dtype 7176) shoul d be used
to ai d i n assuri ng opti mum transmi ssi on perfor-
mance. Fl ui ds of the type l abel ed DEXRON I I Auto-
mati c Transmi ssi on Fl ui d are not recommended. I t
i s i mportant that the transmi ssi on fl ui d be mai n-
tai ned at the prescri bed l evel usi ng the recommended
fl ui ds.
SPECIAL ADDITIVES
Chrysl er Corporati on does not recommend the
addi ti on of any fl ui ds to the transaxl e, other than the
fl ui d l i sted above. An excepti on to thi s pol i cy i s the
use of speci al dyes to ai d i n detecti ng fl ui d l eaks. The
use of transmi ssi on seal ers shoul d be avoi ded, si nce
they may adversel y affect seal s.
CLUTCH AND GEAR
The transaxl e consi sts of:
Three mul ti pl e di sc i nput cl utches
Two mul ti pl e di sc grounded cl utches
Four hydraul i c accumul ators
Two pl anetary gear sets
Thi s provi des four forward rati os and a reverse
rati o. The i nput cl utch-appl y pi stons were desi gned
wi th centri fugal l y bal anced oi l cavi ti es so that qui ck
response and good control can be achi eved at any
speed. A push/pul l pi ston i s i ncorporated for two of
the three i nput cl utches.
CAUTION: Some clutch packs appear similar, but
they are not the same. Do not interchange clutch
components, as they might fail.
HYDRAULICS
The hydraul i cs of the transaxl e provi de:
Manual shi ft l ever sel ect functi on
Mai n l i ne pressure regul ati on
Torque converter and cool er fl ow control
Oi l fl ow to the fri cti on el ements i s control l ed
di rectl y by four sol enoi d val ves. The hydraul i cs al so
i ncl ude a uni que l ogi c- control l ed sol enoi d torque con-
verter cl utch control val ve. Thi s val ve l ocks out the
1st gear reacti on el ement wi th the appl i cati on of 2nd,
di rect, or overdri ve gear el ements. I t al so redi rects
the 1st gear sol enoi d output so that i t can control
torque converter cl utch operati on. To regai n access to
1st gear, a sequence of commands must be used to
move the sol enoi d TCC control val ve. Thi s precl udes
any appl i cati on of the 1st gear reacti on el ement wi th
other el ements appl i ed. I t al so al l ows one sol enoi d to
control two fri cti on el ements.
Smal l , hi gh-rate accumul ators are provi ded i n each
control l ed fri cti on el ement ci rcui t. These serve to
absorb the pressure responses, and al l ow the control s
to read and respond to changes that are occurri ng.
SOLENOIDS
The sol enoi d val ves perform most control functi ons,
these val ves must be extremel y durabl e and tol erant
of di rt. For that reason hardened-steel poppet and
bal l val ves are used. These are free from any cl ose
operati ng cl earances. The sol enoi ds operate the
val ves di rectl y wi thout any i ntermedi ate el ement.
Di rect operati on means that these uni ts must have
very hi gh output. They must cl ose agai nst the si ze-
abl e fl ow areas and hi gh l i ne pressures. Fast
response i s al so requi red to meet the control requi re-
ments.
Two of the sol enoi ds are normal l y-venti ng and two
are normal l y-appl yi ng; thi s was done to provi de a
defaul t mode of operati on. Wi th no el ectri cal power,
the transmi ssi on provi des 2nd gear i n (OD), (3), or
(L) shi ft l ever posi ti ons. Al l other transmi ssi on l ever
posi ti ons wi l l operate normal l y. The choi ce of 2nd
gear was made to provi de adequate breakaway per-
formance whi l e sti l l accommodati ng hi ghway speeds.
SENSORS
There are three pressure swi tches to i denti fy sol e-
noi d appl i cati on. There are two speed sensors to read
i nput (torque converter turbi ne) and output (parki ng
sprag) speeds. There i s al so a transmi ssi on range
sensor to i ndi cate the manual shi ft l ever posi ti on.
The pressure swi tches are i ncorporated i n an assem-
bl y wi th the sol enoi ds. Engi ne speed, throttl e posi -
ti on, temperature, etc., are al so observed. Some of
these si gnal s are read di rectl y from the engi ne con-
trol sensors; others are read from a mul ti pl ex ci rcui t
wi th the powertrai n control modul e.
ELECTRONICS
The 41TE Transmi ssi on Control Modul e (TCM) i s
l ocated underhood i n a potted, di e-cast al umi num
housi ng. The modul e used i s a new control l er cal l ed
EATX I I I . The TCM has a seal ed, 60-way connector.
ADAPTIVE CONTROLS
These control s functi on by readi ng the i nput and
output speeds over 140 ti mes a second and respond-
i ng to each new readi ng. Thi s provi des the preci se
and sophi sti cated fri cti on el ement control needed to
make smooth cl utch-to-cl utch shi fts for al l gear
changes. The use of overrunni ng cl utches or other
shi ft qual i ty ai ds are not requi red. As wi th most
automati c transaxl es, al l shi fts i nvol ve rel easi ng one
el ement and appl yi ng a di fferent el ement. I n si mpl i -
fi ed terms, the upshi ft l ogi c al l ows the rel easi ng el e-
ment to sl i p backwards sl i ghtl y. Thi s ensures that i t
does not have excess capaci ty. The appl y el ement i s
fi l l ed unti l i t begi ns to make the speed change to the
hi gher gear. The appl y pressure i s then control l ed to
mai ntai n the desi red rate of speed change. Thi s con-
ti nues unti l the shi ft i s made. The key to provi di ng
excel l ent shi ft qual i ty i s preci si on. For exampl e, the
rel ease el ement for upshi fts i s al l owed to sl i p back-
wards sl i ghtl y. The amount of that sl i p i s typi cal l y
l ess than a total of 20 degrees. To achi eve that pre-
ci si on, the TCM l earns the trai ts of the transaxl e
that i t i s control l i ng. I t l earns the rel ease rate of the
rel easi ng el ement and the appl y ti me of the appl yi ng
el ement. I t al so l earns the rate at whi ch the appl y
el ement bui l ds pressure suffi ci ent to begi n maki ng
the speed change. Thi s method achi eves more preci -
si on than woul d be possi bl e wi th exacti ng tol erances.
I t can al so adapt to any changes that occur wi th age
or envi ronment.
For ki ckdown shi fts, the control l ogi c al l ows the
rel easi ng el ement to sl i p. Then control s the rate at
whi ch the i nput (and engi ne) accel erate. When the
l ower gear speed i s achi eved, the rel easi ng el ement
reappl i es to mai ntai n that speed unti l the appl y el e-
ment i s fi l l ed. Thi s provi des qui ck response si nce the
engi ne begi ns to accel erate i mmedi atel y. Thi s al so
provi des a smooth torque exchange si nce the rel ease
el ement can control the rate of torque i ncrease. Thi s
control can make any powertrai n feel more respon-
si ve wi thout i ncreasi ng harshness.
Adapti ve control s respond to i nput speed changes.
They compensate for changes i n engi ne or fri cti on
el ement torque and provi de good, consi stent shi ft
qual i ty for the l i fe of the transaxl e.
TORQUE MANAGEMENT
Most 41TE transaxl es uti l i ze torque management.
Torque management i s a uni que functi on of the Pow-
ertrai n Control Modul e (PCM). The PCM recei ves
output si gnal s from the Transmi ssi on Control Modul e
(TCM) and many vari ous engi ne sensors. The PCM
eval uates these si gnal s and deci des i f i t i s necessary
to decrease the output of the engi nes torque. Thi s
reducti on i n torque does not i nterfere wi th the nor-
mal operati on of the vehi cl e. Thi s reducti on i n torque
wi l l prol ong the l i fe of the dri vetrai n components.
Torque reducti on i s not noti ceabl e i n normal dri vi ng
functi ons. The torque reducti on functi on shuts off
above 16 MPH.
ON-BOARD DIAGNOSTICS
Thi s vehi cl e uti l i zes a di agnosti c system cal l ed
OBDI I . The powertrai n control modul e communi cates
wi th the Transmi ssi on Control Modul e. Whenever
the transaxl e sets a faul t i n the Transmi ssi on Con-
trol Modul e (dependent on whi ch faul t i s set), the
powertrai n control modul e wi l l turn on a MI L (Mal -
functi on I ndi cator Lamp) on the i nstrument cl uster.
By readi ng the code i n the powertrai n control modul e
i t wi l l tel l you where the faul t occurred. I f the faul t
occurred i n the transaxl e, the control l er wi l l read a
CODE 45. For further i nformati on regardi ng OBDI I ,
refer to Group 25, Emi ssi on Systems.
These control s provi de comprehensi ve, on-board
transaxl e di agnosti cs. The i nformati on avai l abl e can
ai d i n transaxl e di agnosi s. For exampl e, appl y el e-
ment bui l dup rate i ndi cates sol enoi d performance.
Al so i ncl uded are sel f di agnosti c functi ons. Sel f di ag-
nosti cs al l ow the techni ci an to test the condi ti on of
the el ectroni c control s. The Transmi ssi on Control
Modul e conti nuousl y moni tors i ts cri ti cal functi ons. I t
al so records any mal functi ons, and the number of
engi ne starts si nce the l ast mal functi on. Thi s al l ows
the techni ci an to use the i nformati on i n the event of
a customer compl ai nt.
TRANSMISSION CONTROL MODULE
Do not i nterchange Transmi ssi on Control Modul es
wi th previ ous year transmi ssi on control modul es. I f a
same year TCM i s bei ng used from a di fferent vehi -
cl e, the fol l owi ng procedures must be performed:
Qui ck Learn Procedure
El ectroni c Pi ni on Factor Procedure
The Transmi ssi on Control Modul e i s l ocated on the
ri ght i nner fender panel , i n the engi ne compartment.
I t i s hel d i n pl ace by four mounti ng screws.
NOTE: If the Transmission Control Module has
been replaced, the following procedures must be
performed:
Qui ck Learn Procedure: Thi s procedure wi l l
al l ow the transmi ssi on control modul e to l earn the
characteri sti cs of the vehi cl e.
El ectroni c Pi ni on Factor Procedure: Thi s proce-
dure wi l l reprogram the TCM to compensate for di f-
ferent ti re si zes and fi nal dri ve rati os.
GEARSHIFT AND PARKING LOCK CONTROLS
The transaxl e i s control l ed by a l ever type gear-
shi ft i ncorporated wi thi n the steeri ng col umn. The
control has si x sel ector l ever posi ti ons: P (park), R
(reverse), N (neutral ), and D (dri ve), 2 (second), and
1 (fi rst). The parki ng l ock i s appl i ed by movi ng the
sel ector l ever past a gate to the P posi ti on. Do not
apply the parking lock until the vehicle has
stopped; otherwise, a severe ratchet noise will
occur.
TRANSMISSION RANGE SENSOR
The 41TE transaxl e i s equi pped wi th a transmi s-
si on range sensor that i s l ocated on top of the val ve
body. Thi s sensor wi l l al l ow for accurate transmi ssi on
gear posi ti on measurement.
To servi ce the transmi ssi on range sensor (TRS),
you must remove the val ve body. For repai r proce-
dures, refer to the Removal and I nstal l ati on secti on
wi thi n thi s group.
Al so l ocated wi thi n the TRS i s a transmi ssi on tem-
perature sensor. Thi s sensor i s used to measure the
transmi ssi on fl ui d sump temperature. The transmi s-
si on temperature sensor i s servi ced wi th the TRS as
a uni t.
SHIFT POSITION INDICATOR
The shi fter posi ti on i ndi cator i s l ocated i n the
i nstrument cl uster. The shi fter posi ti on i ndi cator out-
l i nes wi th a box the gear posi ti on the transaxl e man-
ual val ve l ever i s i n.
The transmi ssi on range sensor (l ocated on the
val vebody) sends a si gnal to the TCM on the posi ti on
of the transaxl e manual val ve l ever. The TCM
recei ves the swi tch si gnal and processes the data.
The TCM sends the Shi ft Lever Posi ti on (SLP) i nfor-
mati on to the BCM vi a the CCD bus. The BCM then
outl i nes wi th a box the appropri ate shi fter posi ti on
i ndi cator i n the i nstrument cl uster.
To repl ace the shi fter posi ti on i ndi cator, refer to
Group 8E, I nstrument Panel And Gauges.
41TE TRANSAXLE GENERAL DIAGNOSIS
CAUTION: Before attempting any repair on a 41TE
four speed automatic transaxle, check for Diagnos-
tic Trouble Codes with the DRBIII scan tool. Always
use the Powertrain Diagnostic Test Procedure Man-
ual.
Transaxl e mal functi ons may be caused by these
general condi ti ons:
Poor engi ne performance
I mproper adjustments
Hydraul i c mal functi ons
Mechani cal mal functi ons
El ectroni c mal functi ons
Di agnosi s of these probl ems shoul d al ways begi n
by checki ng the easi l y accessi bl e vari abl es: fl ui d l evel
and condi ti on, gearshi ft cabl e adjustment. Then per-
form a road test to determi ne i f the probl em has been
corrected or that more di agnosi s i s necessary. I f the
probl em persi sts after the prel i mi nary tests and cor-
recti ons are compl eted, hydraul i c pressure checks
shoul d be performed.
ROAD TEST
Pri or to performi ng a road test, check the fl ui d
l evel .
Duri ng the road test, the transaxl e shoul d be oper-
ated i n each posi ti on to check for sl i ppi ng and any
vari ati on i n shi fti ng.
I f vehi cl e operates properl y at hi gh speeds, but has
poor accel erati on, the converters overrunni ng cl utch
may be sl i ppi ng. I f accel erati on i s normal , but hi gh
throttl e openi ng i s needed for hi gh speeds, the cl utch
may have sei zed. Both of these stator defects requi re
repl acement of the torque converter.
The cl utch that i s sl i ppi ng can be determi ned by
noti ng the transaxl e operati on i n al l sel ector posi -
ti ons. Then compari ng whi ch i nternal uni ts are
appl i ed i n those posi ti ons. The Elements in Use
Chart provi des a basi s for road test anal ysi s.
The process of el i mi nati on can be used to detect
any uni t whi ch sl i ps and to confi rm proper operati on
of good uni ts. Road test anal ysi s can usual l y di ag-
nose sl i ppi ng uni ts. However, the actual cause of the
mal functi on may not be detected. Practi cal l y any con-
di ti on can be caused by l eaki ng hydraul i c ci rcui ts or
sti cki ng val ves.
HYDRAULIC PRESSURE TESTS
Pressure testi ng i s a very i mportant step i n the
di agnosti c procedure. These tests usual l y reveal the
cause of most hydraul i c transaxl e probl ems.
Before performi ng pressure tests, be certai n that
fl ui d l evel and condi ti on, and shi ft cabl e adjustments
have been checked and approved. Fl ui d must be at
operati ng temperature (150 to 200 degrees F.).
I nstal l an engi ne tachometer, rai se vehi cl e on hoi st
whi ch al l ows front wheel s to turn, and posi ti on
tachometer so i t can be read.
ELEMENTS IN USE AT EACH POSITION OF THE SELECTOR LEVER
Attach 150 psi gauges to ports requi red for test
bei ng conducted. A 300 psi gauge (C-3293) i s requi red
for reverse pressure test.
Test port l ocati ons are shown i n (Fi g. 2).
TEST ONE-SELECTOR IN LOW 1st GEAR
(1) Attach pressure gauge to the l ow/reverse cl utch
tap.
(2) Move sel ector l ever to the (L) posi ti on.
(3) Al l ow vehi cl e wheel s to turn and i ncrease
throttl e openi ng to achi eve an i ndi cated vehi cl e speed
to 20 mph.
(4) Low/reverse cl utch pressure shoul d read 115 to
145 psi .
(5) Thi s test checks pump output, pressure regul a-
ti on and condi ti on of the l ow/reverse cl utch hydraul i c
ci rcui t and shi ft schedul e.
TEST TWO-SELECTOR IN DRIVE 2nd GEAR
NOTE: This test checks the underdrive clutch
hydraulic circuit as well as the shift schedule.
(1) Attach gauge to the underdri ve cl utch tap.
(2) Move sel ector l ever to the 3 posi ti on.
of 30 mph.
(4) I n second gear the underdri ve cl utch pressure
shoul d read 110 to 145 psi .
TEST 2ASELECTOR IN OD
NOTE: This test checks the underdrive clutch
hydraulic circuit as well as the shift schedule.
(1) Attach gauge to the UD cl utch tap.
(2) Move sel ector l ever to the OD posi ti on.
(3) Al l ow wheel s to rotate freel y and i ncrease
throttl e openi ng to achi eve an i ndi cated speed of 40
mph.
(4) Underdri ve cl utch pressure shoul d read bel ow
5 psi . I f not, than ei ther the sol enoi d assembl y or
TCM i s at faul t.
TEST THREE-OVERDRIVE CLUTCH CHECK
(1) Attach gauge to the overdri ve cl utch tap.
(2) Move sel ector l ever to the (Ci rcl e D) posi ti on.
of 20 mph.
(4) Overdri ve cl utch pressure shoul d read 74 to 95
psi .
(5) Move sel ector l ever to the (3) posi ti on and
i ncrease i ndi cated vehi cl e speed to 30 mph.
(6) The vehi cl e shoul d be i n second gear and over-
dri ve cl utch pressure shoul d be l ess than 5 psi .
(7) Thi s test checks the overdri ve cl utch hydraul i c
ci rcui t as wel l as the shi ft schedul e.
TEST FOUR-SELECTOR IN CIRCLE DRIVE,
OVERDRIVE GEAR
(1) Attach gauge to the 2/4 cl utch tap.
(3) Al l ow vehi cl e front wheel s to turn and i ncrease
of 30 mph.
(4) The 2/4 cl utch pressure shoul d read 75 to 95
psi .
(5) Thi s test checks the 2/4 cl utch hydraul i c ci r-
cui t.
TEST FIVE-SELECTOR IN CIRCLE DRIVE,
OVERDRIVE
(1) Attach gauge to the torque converter cl utch off
pressure tap.
of 50 mph.
CAUTION: Both wheels must turn at the same
speed.
(4) Torque converter cl utch off pressure shoul d be
l ess than 5 psi .
(5) Thi s test checks the torque converter cl utch
hydraul i c ci rcui t.
TEST SIX-SELECTOR IN REVERSE
(1) Attach gauge to the reverse and LR cl utch tap.
(2) Move sel ector l ever to the reverse posi ti on.
(3) Read reverse cl utch pressure wi th output sta-
ti onary (foot on brake) and throttl e opened to achi eve
1500 rpm.
Fig. 2 Pressure Taps
(4) Reverse and LR cl utch pressure shoul d read
165 to 235 psi .
(5) Thi s test checks the reverse cl utch hydraul i c
ci rcui t.
TEST RESULT INDICATIONS
(1) I f proper l i ne pressure i s found i n any one test,
the pump and pressure regul ator are worki ng prop-
erl y.
(2) Low pressure i n al l posi ti ons i ndi cates a defec-
ti ve pump, a cl ogged fi l ter, or a stuck pressure regu-
l ator val ve.
(3) Cl utch ci rcui t l eaks are i ndi cated i f pressures
do not fal l wi thi n the speci fi ed pressure range.
(4) I f the overdri ve cl utch pressure i s greater than
5 psi i n Step 4 of Test Three, a worn reacti on shaft
seal ri ng or a defecti ve sol enoi d assembl y i s i ndi -
cated.
(5) I f the underdri ve cl utch pressure i s greater
than 5 psi i n Step 4 of Test 2A, a defecti ve sol enoi d
assembl y or TCM i s the cause.
CLUTCH AIR PRESSURE TESTS
I noperati ve cl utches can be l ocated usi ng a seri es
of tests by substi tuti ng ai r pressure for fl ui d pressure
(Fi g. 3) (Fi g. 4). The cl utches may be tested by appl y-
i ng ai r pressure to thei r respecti ve passages. The
val ve body must be removed and Tool 6056 i nstal l ed.
To make ai r pressure tests, proceed as fol l ows:
NOTE: The compressed air supply must be free of
all dirt and moisture. Use a pressure of 30 psi.
Remove oi l pan and val ve body. See Val ve body
removal .
OVERDRIVE CLUTCH
Appl y ai r pressure to the overdri ve cl utch appl y
passage and watch for the push/pul l pi ston to move
forward. The pi ston shoul d return to i ts starti ng
posi ti on when the ai r pressure i s removed.
PRESSURE CHECK SPECIFICATIONS
REVERSE CLUTCH
Appl y ai r pressure to the reverse cl utch appl y pas-
sage and watch for the push/pul l pi ston to move rear-
ward. The pi ston shoul d return to i ts starti ng
posi ti on when the ai r pressure i s removed.
2/4 CLUTCH
Appl y ai r pressure to the feed hol e l ocated on the
2/4 cl utch retai ner. Look i n the area where the 2/4
pi ston contacts the fi rst separator pl ate and watch
careful l y for the 2/4 pi ston to move rearward. The
pi ston shoul d return to i ts ori gi nal posi ti on after the
ai r pressure i s removed.
LOW/REVERSE CLUTCH
Appl y ai r pressure to the l ow/reverse cl utch feed
hol e (rear of case, between 2 bol t hol es). Then, l ook
i n the area where the l ow/reverse pi ston contacts the
fi rst separator pl ate. Watch careful l y for the pi ston to
move forward. The pi ston shoul d return to i ts ori gi -
nal posi ti on after the ai r pressure i s removed.
UNDERDRIVE CLUTCH
Because thi s cl utch pi ston cannot be seen, i ts oper-
ati on i s checked by functi on. Ai r pressure i s appl i ed
to the l ow/reverse and the 2/4 cl utches. Thi s l ocks the
output shaft. Use a pi ece of rubber hose wrapped
around the i nput shaft and a pai r of cl amp-on pl i ers
to turn the i nput shaft. Next appl y ai r pressure to
the underdri ve cl utch. The i nput shaft shoul d not
rotate wi th hand torque. Rel ease the ai r pressure
and confi rm that the i nput shaft wi l l rotate.
FLUID LEAKAGE-TORQUE CONVERTER HOUSING
AREA
(1) Check for source of l eakage.
(2) Fl ui d l eakage at or around the torque converter
area may ori gi nate from an engi ne oi l l eak. The area
shoul d be exami ned cl osel y. Factory fi l l fl ui d i s red
and, therefore, can be di sti ngui shed from engi ne oi l .
(3) Pri or to removi ng the transaxl e, perform the
fol l owi ng checks:
(4) When l eakage i s determi ned to ori gi nate from
the transaxl e, check fl ui d l evel pri or to removal of
the transaxl e and torque converter.
(5) Hi gh oi l l evel can resul t i n oi l l eakage out the
vent i n the manual shaft. I f the fl ui d l evel i s hi gh,
adjust to proper l evel .
(6) After performi ng thi s operati on, i nspect for
l eakage. I f a l eak persi sts, perform the fol l owi ng
operati on on the vehi cl e. Thi s wi l l determi ne i f the
torque converter or transaxl e i s l eaki ng.
TORQUE CONVERTER LEAKAGE
Possi bl e sources of torque converter l eakage are:
Torque converter wel d l eaks at the outsi de
(peri pheral ) wel d.
Torque converter hub wel d.
NOTE: Hub weld is inside and not visible. Do not
attempt to repair. Replace torque converter.
SHIFT POSITION INDICATOR
The transmi ssi on range sensor (on the val ve body)
sends a si gnal to the TCM on the posi ti on of the
transaxl e manual val ve l ever. The TCM recei ves the
swi tch si gnal and processes the data. The TCM sends
the Shi ft Lever Posi ti on (SLP) i nformati on to the
BCM vi a the CCD bus. The BCM then outl i nes wi th
a box the appropri ate shi fter posi ti on i ndi cator i n the
Fig. 3 Air Pressure Test Plate
Fig. 4 Testing Reverse Clutch
I f a probl em ari ses wi th the shi fter posi ti on i ndi ca-
tor, consul t the fol l owi ng chart for di agnosti c i nfor-
mati on. I f the mal functi on cannot be corrected usi ng
the chart, consul t the proper di agnosti c manual .
To repl ace the shi fter posi ti on i ndi cator, refer to
Group 8E, I nstrument Panel And Gauges.
SERVICE PROCEDURES
FLUID AND FILTER CHANGE
When the factory fi l l fl ui d i s changed, onl y fl ui ds
l abel ed MOPAR ATF PLUS 3 (Automati c Transmi s-
si on fl ui d) Type 7176 shoul d be used.
I f the transaxl e i s di sassembl ed for any reason, the
fl ui d and fi l ter shoul d be changed.
30,000 MILE TRANSAXLE OIL CHANGE
When a vehi cl e attai ns 30,000 mi l es on i ts odome-
ter i t i s recommended that the transaxl e oi l be
changed. To change the oi l , use the procedure that
fol l ows:
I t i s recommended that a transaxl e fl ui d exchanger
(ATF 2000+ or equi val ent) be used to repl ace the
used fl ui d i n the transaxl e. I f a fl ui d exchanger i s not
avai l abl e use a fl ui d sucti on pump (Vacul a or equi v-
al ent) to draw the fl ui d out of the di psti ck tube. I f a
fl ui d sucti on pump i s not avai l abl e remove the oi l
pan and drai n the fl ui d.
CAUTION: Chrysler Corporation does not recom-
mend using any fluid exchanger that introduces
additives into the transaxle.
TRANSAXLE FLUID EXCHANGER METHOD
(1) To perform the transaxl e fl ui d exchange, the
transaxl e must be at operati ng temperature. Dri ve
the vehi cl e ti l l i t reaches ful l operati ng temperature.
(2) Veri fy that the fi l l tank on the transaxl e fl ui d
exchanger (ATF 2000+ or equi val ent) i s cl ean and
dry.
(3) Fi l l the tank to the recommended fi l l capaci ty
wi th Mopar ATF Pl us 3 Type 7176.
(4) Hookup the vehi cl e to the machi ne fol l owi ng
the manufacturers i nstructi ons. Perform the
exchange procedure fol l owi ng the i nstructi ons pro-
vi ded wi th the machi ne.
(5) Once machi ne has compl eted the fl ui d
exchange. Check the fl ui d l evel and condi ti on and fi l l
to proper l evel wi th Mopar ATF Pl us 3 Type 7176.
NOTE: Verify that the transaxle cooler lines are
tightened to proper specifications. Cooler line
torque specification is 2 Nm (18 in. lbs.).
CONDITION POSSIBLE CAUSE
ALL PRND3L DISPLAY
LIGHTS ON IN P&N
GEAR POSITIONS
1.Check wiring and
connectors
2. Faulty trans. range
sensor
3. Faulty manual lever
ALL DISPLAY LIGHTS
ON IN ALL GEAR
POSITIONS
1. Check wiring &
connectors
sensor
4. CCD communication
malfunction
5. Check oil level
ALL DISPLAY LIGHTS
OFF
1. Normal transient
condition between P&R
and R&N gear positions
2. Check shift lever
linkage
3. Body controller
malfunction
4. Check wiring and
connectors
5. Faulty cluster
ALL DISPLAY LIGHTS
OFF ACCOMPANIED
BY A NO BUS
MESSAGE
malfunction
DISPLAY LIGHTS OUT
OF SEQUENCE WITH
SHIFT LEVER
1. Check wiring and
connectors
sensor
malfunction
DIPSTICK TUBE FLUID SUCTION METHOD
(1) When performi ng the fl ui d sucti on method,
make sure the transaxl e i s at ful l operati ng temper-
ature.
(2) To perform the di psti ck tube fl ui d sucti on
method, use a sui tabl e fl ui d sucti on devi ce (Vacul a
or equi val ent).
(3) I nsert the fl ui d sucti on l i ne i nto the di psti ck
tube.
NOTE: Verify that the suction line is inserted to the
lowest point of the transaxle oil pan. This will
ensure complete evacuation of the fluid in the pan.
(4) Fol l ow the manufacturers recommended proce-
dure and evacuate the fl ui d from the transaxl e.
(5) Remove the sucti on l i ne from the di psti ck tube.
(6) Add 4 Quarts of Mopar ATF Pl us 3 Type 7176
transaxl e fl ui d.
neutral or park.
sti ck.
the HOT range.
TRANSAXLE OIL PAN DROP METHOD
Thi s procedure i nvol ves removi ng the transaxl e oi l
pan to drai n the transaxl e fl ui d.
to 19 Nm (165 i n. l bs.).
neutral or park.
sti ck.
the HOT range. Dri ve the vehi cl e a mi ni mum of 10
mi l es.
(11) Check for l eaks around the transaxl e oi l pan
seal i ng surfaces.
(12) Recheck the fl ui d l evel . The l evel shoul d be i n
the HOT range.
SEVERE USAGE SERVICE
I f the vehi cl e exhi bi ts any of the fol l owi ng symp-
toms, i t i s recommended that the transaxl e oi l and
fi l ter be repl aced.
Transaxl e oi l di scol ored
Transaxl e oi l has hi gh mi l eage
Oi l feel s gri my when rubbed between fi ngerti ps
Poor shi ft qual i ty
Del ayed gear engagement
Vehi cl e shudder between shi fts
TRANSAXLE OIL AND FILTER REPLACEMENT
Thi s procedure i nvol ves changi ng the transaxl e
fl ui d and fi l ter, dri vi ng the vehi cl e for 10 mi l es and
changi ng the transaxl e fl ui d a second ti me.
(5) Separate the fi l ter and O-ri ng from the val ve
body. I nspect the O-ri ng for cuts or i mproper i nstal -
l ati on. Thi s coul d l ead to del ayed garage shi fts.
(6) I nstal l a new fi l ter. Repl ace the O-ri ng as nec-
essary.
to 19 Nm (165 i n. l bs.).
neutral or park.
sti ck.
i n the HOT range. Dri ve the vehi cl e a mi ni mum of
10 mi l es.
(13) Remove the pan and cl ean al l seal ant from
the pan and transaxl e mati ng surfaces. Cl ean the
magnet and the i nsi de of the pan.
(14) Separate the fi l ter from the val ve body to
al l ow addi ti onal fl ui d to drai n from the transaxl e.
I nspect the fi l ter O-ri ng for any damage and repl ace
as necessary.
(15) After the transaxl e has stopped drai ni ng,
rei nstal l the fi l ter and O-ri ng.
(16) Appl y a 1/8 i nch bead of Mopar RTV Seal ant
to the mounti ng fl ange of the transaxl e oi l pan.
Appl y RTV Seal ant to the undersi de of the attachi ng
bol ts. Attach the oi l pan to the transaxl e. Ti ghten the
neutral or park.
sti ck.
i n the HOT range.
FLUID DRAIN AND REFILL
(1) Rai se vehi cl e on a hoi st (See Group 0, Lubri ca-
ti on). Pl ace a drai n contai ner wi th a l arge openi ng,
under transaxl e oi l pan.
(2) Loosen pan bol ts and tap the pan at one corner
to break i t l oose al l owi ng fl ui d to drai n, then remove
the oi l pan.
(3) I nstal l a new fi l ter and O-ri ng on bottom of the
val ve body.
(4) Cl ean the oi l pan and magnet. Rei nstal l pan
usi ng new MOPAR RTV seal ant. Ti ghten oi l pan
(5) Pour four quarts of MOPAR ATF PLUS 3
(Automati c Transmi ssi on Fl ui d) Type 7176 through
the fi l l tube.
(6) Start engi ne and al l ow to i dl e for at l east one
mi nute. Then, wi th parki ng and servi ce brakes
appl i ed, move sel ector l ever momentari l y to each
posi ti on, endi ng i n the park or neutral posi ti on.
(7) Add suffi ci ent fl ui d to bri ng l evel to 1/8 i nch
bel ow the ADD mark.
CAUTION: Do not overfill transaxle. Do not add oil
if level is between: Lower holes for warm oil
(100F). Upper holes for hot oil (180F).
(8) Recheck fl ui d l evel after transaxl e i s at normal
operati ng temperature. The l evel shoul d be i n the
HOT regi on (Fi g. 5).
(9) To prevent di rt from enteri ng transaxl e, make
certai n that di psti ck i s seated i nto the di psti ck fi l l
tube.
ALUMINUM THREAD REPAIR
Damaged or worn threads i n the al umi num tran-
saxl e case and val ve body can be repai red by the use
of Hel i -Coi l s, or equi val ent. Thi s repai r consi sts of
dri l l i ng out the worn-out damaged threads. Then tap
the hol e wi th a speci al Hel i -Coi l tap, or equi val ent,
and i nstal l i ng a Hel i -Coi l i nsert, or equi val ent, i nto
the hol e. Thi s bri ngs the hol e back to i ts ori gi nal
thread si ze.
Hel i -Coi l , or equi val ent, tool s and i nserts are
readi l y avai l abl e from most automoti ve parts suppl i -
ers.
FLUSHING COOLERS AND TUBES
When a transaxl e fai l ure has contami nated the
fl ui d, the oi l cool er(s) must be fl ushed. The cool er
bypass val ve i n the transaxl e must be repl aced al so.
The torque converter must al so be repl aced wi th an
exchange uni t. Thi s wi l l i nsure that metal parti cl es
or sl udged oi l are not l ater transferred back i nto the
recondi ti oned (or repl aced) transaxl e.
The recommended procedure for fl ushi ng the tran-
saxl e cool er i s to use Tool 6906A Cool er Fl usher.
Fig. 5 Oil Level Indicator
WARNING: WEAR PROTECTIVE EYEWEAR THAT
MEETS THE REQUIREMENTS OF OSHA AND ANSI
Z87.11968. WEAR STANDARD INDUSTRIAL RUB-
BER GLOVES.
KEEP LIGHTED CIGARETTES, SPARKS, FLAMES,
AND OTHER IGNITION SOURCES AWAY FROM THE
AREA TO PREVENT THE IGNITION OF COMBUSTI-
BLE LIQUIDS AND GASES. KEEP A CLASS (B) FIRE
EXTINGUISHER IN THE AREA WHERE THE
FLUSHER WILL BE USED.
KEEP THE AREA WELL VENTILATED.
DO NOT LET FLUSHING SOLVENT COME IN CON-
TACT WITH YOUR EYES OR SKIN: IF EYE CONTAM-
INATION OCCURS, FLUSH EYES WITH WATER FOR
15 TO 20 SECONDS. REMOVE CONTAMINATED
CLOTHING AND WASH AFFECTED SKIN WITH
SOAP AND WATER. SEEK MEDICAL ATTENTION.
COOLER FLUSH USING TOOL 6906A
(1) Remove cover pl ate fi l l er pl ug on Tool 6906A.
Fi l l reservoi r 1/2 to 3/4 ful l of fresh fl ushi ng sol uti on.
Fl ushi ng sol vents are petrol eum based sol uti ons gen-
eral l y used to cl ean automati c transmi ssi on compo-
nents. DO NOT use sol vents contai ni ng aci ds, water,
gasol i ne, or any other corrosi ve l i qui ds.
(2) Rei nstal l fi l l er pl ug on Tool 6906A.
(3) Veri fy pump power swi tch i s turned OFF. Con-
nect red al l i gator cl i p to posi ti ve (+) battery post.
Connect bl ack (-) al l i gator cl i p to a good ground.
(4) Di sconnect the cool er l i nes at the transmi ssi on.
NOTE: When flushing transmission cooler and
lines, ALWAYS reverse flush.
(5) Connect the BLUE pressure l i ne to the OUT-
LET (From) cool er l i ne.
(6) Connect the CLEAR return l i ne to the I NLET
(To) cool er l i ne
(7) Turn pump ON for two to three mi nutes to
fl ush cool er(s) and l i nes. Moni tor pressure readi ngs
and cl ear return l i nes. Pressure readi ngs shoul d sta-
bi l i ze bel ow 20 psi . for vehi cl es equi pped wi th a si n-
gl e cool er and 30 psi . for vehi cl es equi pped wi th dual
cool ers. I f fl ow i s i ntermi ttent or exceeds these pres-
sures, repl ace cool er.
(8) Turn pump OFF.
(9) Di sconnect CLEAR sucti on l i ne from reservoi r
at cover pl ate. Di sconnect CLEAR return l i ne at
cover pl ate, and pl ace i t i n a drai n pan.
(10) Turn pump ON for 30 seconds to purge fl ush-
i ng sol uti on from cool er and l i nes. Turn pump OFF.
(11) Pl ace CLEAR sucti on l i ne i nto a one quart
contai ner of Mopar ATF PLUS 3 Type 7176 auto-
mati c transmi ssi on fl ui d.
(12) Turn pump ON unti l al l transmi ssi on fl ui d i s
removed from the one quart contai ner and l i nes. Thi s
purges any resi dual cl eani ng sol vent from the trans-
mi ssi on cool er and l i nes. Turn pump OFF.
(13) Di sconnect al l i gator cl i ps from battery. Recon-
nect fl usher l i nes to cover pl ate, and remove fl ushi ng
adapters from cool er l i nes.
OIL PUMP VOLUME CHECK
After the new or repai red transmi ssi on has been
i nstal l ed, fi l l to the proper l evel wi th Mopar ATF
PLUS 3 (Type 7176) automati c transmi ssi on fl ui d.
The vol ume shoul d be checked usi ng the fol l owi ng
procedure:
(1) Di sconnect the From cooler l i ne at the trans-
mi ssi on and pl ace a col l ecti ng contai ner under the
di sconnected l i ne.
CAUTION: With the fluid set at the proper level,
fluid collection should not exceed (1) quart or inter-
nal damage to the transmission may occur.
(2) Run the engi ne at curb idle speed, wi th the
shi ft sel ector i n neutral .
(3) I f fl ui d fl ow i s i ntermi ttent or i t takes more
than 20 seconds to col l ect one quart of ATF, di scon-
nect the To Cooler l i ne at the transaxl e.
(4) Refi l l the transaxl e to proper l evel and recheck
pump vol ume.
(5) I f fl ow i s found to be wi thi n acceptabl e l i mi ts,
repl ace the cool er. Then fi l l transmi ssi on to the
proper l evel , usi ng Mopar ATF PLUS 3 (Type 7176)
automati c transmi ssi on fl ui d.
(6) I f fl ui d fl ow i s sti l l found to be i nadequate,
check the l i ne pressure usi ng the Transaxl e Hydrau-
l i c Pressure Test procedure.
(7) Check the cool er for debri s on the external sur-
faces. Cl ean as necessary.
TRANSAXLE QUICK LEARN PROCEDURE
The qui ck l earn procedure requi res the use of the
DRBI I I scan tool .
Thi s program al l ows the el ectroni c transaxl e sys-
tem to recal i brate i tsel f. Thi s wi l l provi de the best
possi bl e transaxl e operati on. The qui ck l earn proce-
dure shoul d be performed i f any of the fol l owi ng pro-
cedures are performed:
Transaxl e Assembl y Repl acement
Transmi ssi on Control Modul e Repl acement
Sol enoi d Pack Repl acement
Cl utch Pl ate and/or Seal Repl acement
Val ve Body Repl acement or Recondi ti on
To perform the Qui ck Learn Procedure, the fol l ow-
i ng condi ti ons must be met:
The brakes must be appl i ed
The engi ne speed must be above 500 rpm
The throttl e angl e (TPS) must be l ess than 3
degrees
The shi ft l ever posi ti on must stay unti l
prompted to shi ft to overdri ve
The shi ft l ever posi ti on must stay i n overdri ve
after the Shi ft to Overdri ve prompt unti l the DRBI I I
i ndi cates the procedure i s compl ete
The cal cul ated oi l temperature must be above
60 and bel ow 200
(1) Pl ug the DRBI I I scan tool i nto the data l i nk
connector. The connector i s l ocated under the i nstru-
ment panel .
(2) Go to the Transmi ssi on screen.
(3) Go to the Mi scel l aneous screen.
(4) Sel ect Qui ck Learn Procedure. Fol l ow the
i nstructi ons of the DRBI I I to perform the Qui ck
Learn Procedure.
PINION FACTOR PROCEDURE
The vehi cl e speed readi ngs for the speedometer are
taken from the output speed sensor. The TCM must
be cal i brated to the di fferent combi nati ons of equi p-
ment avai l abl e. A procedure has been devel oped
cal l ed Pi ni on Factor. I t al l ows the techni ci an to set
the Transmi ssi on Control Modul e i ni ti al setti ng so
that the speedometer readi ngs wi l l be correct.
Fai l ure to perform thi s procedure wi l l cause a No
Speedometer Operati on condi ti on.
Thi s procedure must be performed i f the Transmi s-
si on Control Modul e has been repl aced.
To properl y read or reset the Pi ni on Factor, i t i s
necessary to use a DRBI I I scan tool . Perform the fol -
l owi ng steps wi th the DRBI I I scan tool to read or
reset the Pi ni on Factor:
(1) Pl ug the DRBI I I scan tool i nto the data l i nk
connector l ocated under the i nstrument panel .
(2) Sel ect the Transmi ssi on menu.
(3) Sel ect the Mi scel l aneous menu.
(4) Sel ect Pi ni on Factor. Then fol l ow the i nstruc-
ti ons on the DRBI I I scan tool screen.
GEARSHIFT CABLE
REMOVAL
(1) Remove cabl e eyel et attachment from transaxl e
operati ng l ever pi n (Fi g. 6).
(2) Usi ng pl i ers, squeeze ears of cabl e condui t
attachment at mounti ng bracket (Fi g. 7) and push
through hol e to remove (Fi g. 8).
(3) Remove the under i nstrument panel si l encer
(Fi g. 9). Refer to Group 8E, I nstrument Panel And
Gauges for more i nformati on.
(4) At the steeri ng col umn attachment, remove the
cabl e eyel et attachment from the shi ft l ever pi n.
(5) Usi ng pl i ers, squeeze ears of cabl e attachment
at mounti ng bracket then push through hol e to
remove.
(6) Unseat the dash grommet and remove the
cabl e from the vehi cl e.
INSTALLATION
(1) I nstal l cabl e i nto steeri ng col umn attachment
bracket. Veri fy condui t ears are ful l y engaged. Veri fy
cabl e does not i nterfere wi th brake pedal actuati on.
(2) Attach cabl e eyel et fi tti ng onto shi ft l ever pi n.
(3) I nsert transaxl e end of cabl e through dash
panel hol e and ful l y seat grommet.
(4) I nstal l i nstrument panel si l encer. Veri fy gear-
shi ft cabl e i s routed through the sl ot i n the si l encer.
CAUTION: Failure to route the cable properly at the
silencer may cause brake pedal interference.
(5) Attach transaxl e end of cabl e to the mounti ng
bracket on the transaxl e. Assure the condui t attach-
ment ears are ful l y seated.
Fig. 6 Gearshift Cable
Fig. 7 Grommet Clips
(6) Attach cabl e eyel et fi tti ng onto the transaxl e
operati ng l ever.
(7) Compl ete adjustment usi ng the gearshi ft cabl e
adjustment procedure.
ADJ USTMENT
posi ti on.
parki ng brake.
adjusted.
cedure.
MANUAL VALVE LEVER (SHIFT LEVER)
REMOVAL
(1) Remove shi ft cabl e from l ever (Fi g. 11).
(2) Loosen the l ever mounti ng bol t (Fi g. 12). Do
not remove bol t (not necessary).
(3) Pul l up on l ever and remove.
INSTALLATION
Fig. 8 Remove Cable From Bracket
Fig. 9 Instrument Panel Silencer
Fig. 10 Gearshift Cable
Fig. 11 Shift Cable
SOLENOID ASSEMBLY-REPLACE
To i nstal l sol enoi d assembl y, reverse removal pro-
cedure. Ti ghten screws to 12 Nm (105 i n. l bs.).
TRANSMISSION RANGE SENSOR
The transmi ssi on range sensor i s l ocated wi thi n
the transaxl e. To remove the TRS the transaxl e oi l
pan and val ve body must be removed.
REMOVAL
(2) Remove engi ne ai r cl eaner and tube.
(3) Remove gearshi ft cabl e (Fi g. 17).
(4) Remove manual val ve l ever.
(5) Di sconnect transmi ssi on range sensor connec-
tor.
(7) Careful l y remove transaxl e oi l pan and drai n
fl ui d.
(8) Remove transaxl e oi l fi l ter. Let transaxl e oi l
drai n ful l y.
(9) Remove val ve body retai ni ng bol ts.
(10) Extract park rod from gui de bracket and
remove val ve body from transaxl e.
(11) Pl ace val ve body on workbench (Fi g. 18).
(12) Remove TRS retai ni ng screw (Fi g. 19).
Fig. 12 Manual Valve Lever (Shift Lever)
Fig. 13 Remove Input Speed Sensor
Fig. 14 Remove Sound Cover
Fig. 15 Remove Attaching Screws
Fig. 16 Remove Solenoid Assembly
(13) Remove manual shaft seal (Fi g. 20).
(14) Sl i de Transmi ssi on Range Sensor up the man-
ual shaft and remove (Fi g. 21).
INSTALLATION
Ti ghten TRS retai ni ng screw to 5 Nm (45 i n. l bs.)
Reseal transaxl e oi l pan usi ng RTV.
SPEED SENSOR-INPUT
CAUTION: When disconnecting speed sensor con-
nector, be sure that the weather seal does not fall
off or remain in old sensor.
The i nput speed sensor i s l ocated to the l eft of the
manual shi ft l ever (Fi g. 22).
SPEED SENSOR-OUTPUT
CAUTION: When disconnecting speed sensor con-
nector, be sure that the weather seal does not fall
off or remain in old sensor.
The output speed sensor i s l ocated to the ri ght of
the manual shi ft l ever (Fi g. 23).
Fig. 17 Gearshift Cable And Manual Valve Lever
Fig. 18 Valve Body W/TRS
Fig. 19 Remove Retaining Screw
Fig. 20 Remove Manual Shaft Seal
Fig. 21 Remove Transmission Range Sensor
TRANSMISSION CONTROL MODULE
Do not i nterchange Transmi ssi on Control Modul es
wi th previ ous year transmi ssi on control modul es. I f a
same year TCM i s bei ng used from a di fferent vehi -
cl e, the fol l owi ng procedures must be performed:
Qui ck Learn Procedure
El ectroni c Pi ni on Procedure
The Transmi ssi on Control Modul e i s l ocated on the
ri ght fender i nner panel , i n the engi ne compartment.
I t i s hel d i n pl ace by four mounti ng screws.
NOTE: If the Transmission Control Module has
been replaced, the following procedures must be
performed:
Qui ck Learn Procedure: Thi s procedure wi l l
al l ow the transmi ssi on control modul e to l earn the
characteri sti cs of the vehi cl e.
El ectroni c Pi ni on Factor Procedure: Thi s proce-
dure wi l l reprogram the TCM to compensate for di f-
ferent ti re si zes and fi nal dri ve rati os.
REMOVAL
(1) Loosen 60 way retai ni ng screw, l ocated i n the
center of the 60 way connector (Fi g. 24). Then di scon-
nect the 60 way connector on Transmi ssi on Control
Modul e.
(2) Remove Transmi ssi on Control Modul e mount-
i ng screws and l i ft modul e from vehi cl e (Fi g. 25) (Fi g.
26).
INSTALLATION
(1) To i nstal l , reverse removal procedure.
Fig. 22 Input (Turbine) Speed Sensor
Fig. 23 Output Speed Sensor
Fig. 24 Loosen Connector Screw
Fig. 25 Mounting Screws
VALVE BODY
REMOVAL
NOTE: To ease removal of the valve body, turn the
manual valve lever fully clockwise.
Fig. 26 Transaxle Control Module
Fig. 27 Remove Oil Pan Bolts
Fig. 28 Remove Oil Pan
Fig. 29 Remove Oil Filter
Fig. 30 Remove Valve Body Attaching Bolts
Fig. 31 Push Park Rod Rollers from Guide Bracket
INSTALLATION
To i nstal l val ve body, reverse removal procedure
CAUTION: The valve body manual shaft pilot may
distort and bind the manual valve if the valve body
is mishandled or dropped.
NOTE: To ease installation of the valve body, turn
the manual valve lever fully clockwise.
Gui de park rod rol l ers i nto gui de bracket, whi l e
shi fti ng manual l ever assembl y out of the i nstal l ati on
posi ti on.
TRANSAXLE
Transaxl e removal does NOT requi re engi ne
removal .
See Group 7, Cool i ng to drai n engi ne cool i ng sys-
tem and remove cool ant return extensi on (3.0 l i ter
engi ne onl y).
The transaxl e and torque converter must be
removed as an assembl y; otherwi se, the torque con-
verter dri ve pl ate, pump bushi ng or oi l seal may be
damaged. The dri ve pl ate wi l l not support a l oad;
therefore, none of the wei ght of the transaxl e shoul d
be al l owed to rest on the dri ve pl ate duri ng removal .
REMOVAL
(2) Remove ai r cl eaner duct. Di sconnect transaxl e
shi ft l i nkage at manual val ve l ever (Fi g. 34).
(3) Squeeze grommet cl i ps and remove cabl e at
transaxl e bracket (Fi g. 35) (Fi g. 36).
(4) Remove 16way engi ne harness connector from
di psti ck tube bracket. Remove di psti ck tube bracket
nut at cyl i nder head. Remove di psti ck tube.
(5) Remove transaxl e cool er l i nes.
(6) Remove connector at transaxl e sol enoi d pack.
(7) Remove i nput and output speed sensor wi ri ng
connectors (Fi g. 37) (Fi g. 38).
Fig. 32 Remove Valve Body
Fig. 33 Valve Body Removed
Fig. 34 Shift Linkage At Manual Valve Lever
Fig. 35 Grommet Clips
(8) Di sconnect el ectri cal connector at transmi ssi on
range sensor.
(9) Remove upper bel l housi ng upper bol ts.
(10) Remove heater tube mounti ng bol t.
(11) Remove vehi cl e speed sensor wi ri ng at sensor.
(12) Remove one rear engi ne mount bol t from top.
(13) Remove rear engi ne mount shi el d screw.
(14) I nstal l engi ne support fi xture and support
engi ne (Fi g. 39).
(15) Rai se vehi cl e. Remove front wheel s. Refer to
Group 2, Suspensi on to remove wheel hub nuts and
both dri ve shafts.
CAUTION: The exhaust flex joint must be discon-
nected from the exhaust manifold anytime the
engine is lowered. If the engine is lowered while the
flex pipe is attached, damage will occur.
(16) Remove bol ts securi ng exhaust fl ex joi nt to
exhaust mani fol d. Di sconnect exhaust pi pe from
mani fol d.
(17) Remove torque converter dust shi el d to gai n
access to torque converter bol ts (Fi g. 40).
Fig. 36 Remove Cable From Bracket
Fig. 37 Input (Turbine) Speed Sensor
Fig. 38 Output Speed Sensor
Fig. 39 Engine Support Fixture
Fig. 40 Remove Torque Converter Dust Shield
(18) Rotate engi ne cl ockwi se to gai n access to
torque converter bol ts (Fi g. 41). Remove torque con-
verter mounti ng bol ts.
(19) Remove front engi ne mount i nsul ator and
bracket (Fi g. 42).
(20) Remove rear engi ne mount shi el d.
(21) Remove rear engi ne mount bracket bol ts and
bracket.
(22) Remove starter bol ts and set starter asi de. Do
not al l ow the starter to hang from battery cabl e (Fi g.
43).
(23) Posi ti on transmi ssi on jack securel y under
transaxl e (Fi g. 44).
(24) Remove l eft fender spl ash shi el d.
(25) Wi th transmi ssi on jack i n posi ti on, remove
the l eft transmi ssi on mount.
(26) Lower transaxl e to access the crankshaft posi -
ti on sensor, remove crankshaft posi ti on sensor from
bel l housi ng. For i nstal l ati on procedure refer to sec-
ti on 8D of thi s servi ce manual .
CAUTION: Remove the crankshaft position sensor
from the bell housing before transmission removal
or installation.
(27) Remove l ower bel l housi ng bol ts.
(28) Careful l y l ower the transaxl e assembl y from
vehi cl e.
INSTALLATION
(1) For i nstal l ati on of transaxl e, reverse the above
procedure.
(2) Check and/or adjust gearshi ft cabl e.
(3) Refi l l transaxl e wi th MOPAR ATF PLUS 3
(Automati c Transmi ssi on Fl ui d) Type 7176.
Fig. 41 Rotate Engine
Fig. 42 Remove Front Engine Mount
Fig. 43 Starter Assembly
Fig. 44 Position Transmission Jack
OIL PUMP SEAL
REMOVAL
INSTALLATION
VALVE BODY RECONDITION
Fig. 45 Remove Oil Pump Seal
Fig. 46 Install Oil Pump Seal
Fig. 47 Transmission Range Sensor Screw
Fig. 48 Transmission Range Sensor Removed
Fig. 49 Manual Shaft and Rooster Comb
Fig. 50 2-4 Accumulator Plate
Fig. 51 TRS, Manual Shaft, and 2-4 Accumulator
Fig. 52 Valve Body Screws
Fig. 53 Valve Body and Transfer Plate
Fig. 54 Transfer Plate and Separator Plate
Fig. 55 Ball Check Location
Fig. 56 Remove Dual Retainer Plate Fig. 57 Springs and Valves Location
TRANSAXLE DISASSEMBLE
NOTE: Tag all clutch pack assemblies, as they are
removed, for reassembly identification.
CAUTION: Do not intermix clutch discs or plates as
the unit might then fail.
(1) Remove i nput and output speed sensors.
(2) Remove transaxl e sol enoi d pack (Fi g. 59).
Fig. 58 Low/Reverse Switch Valve And T/C Limit
Valve
Fig. 59 Remove Solenoid Pack
Fig. 60 Remove Oil Pan Bolts
Fig. 61 Remove Oil Pan
Fig. 62 Remove Oil Filter
NOTE: To ease removal of the valve body, turn the
manual valve fully clockwise.
CAUTION: Do not handle the valve body from the
manual valve. Damage could result.
Fig. 63 Remove Valve Body Attaching Bolts
Fig. 64 Push Park Rod Rollers from Guide Bracket
Fig. 65 Remove Valve Body
Fig. 66 Valve Body Removed
Fig. 67 Remove Accumulators
NOTE: Dependent on engine application, some accu-
mulators will have two springs and others will have
one spring. The springs are color coded according to
application and year. When disassembling, mark accu-
mulator spring location to ease assembly.
Fig. 68 Accumulator (Underdrive)
Fig. 69 Accumulator (Overdrive)
Fig. 70 Remove Low/Reverse Accumulator Snap Ring
Fig. 71 Remove Low/Reverse Accumulator Plug
(Cover)
Fig. 72 Remove Low/Reverse Accumulator Piston
Fig. 73 Remove Low/Reverse Accumulator
Measure the i nput shaft end pl ay wi th the tran-
saxl e i n the verti cal posi ti on. Thi s wi l l ensure that
the measurement wi l l be accurate.
Measuri ng i nput shaft end pl ay before di sassembl y
wi l l usual l y i ndi cate when a #4 thrust pl ate change
i s requi red. The #4 thrust pl ate i s l ocated behi nd the
overdri ve cl utch hub.
Attach a di al i ndi cator to transaxl e bel l housi ng
wi th i ts pl unger seated agai nst end of i nput shaft
(Fi g. 74).
Move i nput shaft i n and out to obtai n end pl ay
readi ng. End pl ay speci fi cati ons are .13 to .64 mm
(.005 to .025 i nch).
Record i ndi cator readi ng for reference when reas-
sembl i ng the transaxl e.
CAUTION: Be sure input speed sensor is removed
before removing oil pump.
OIL PUMP INSPECTION
When di sassembl i ng the transaxl e i t i s necessary
to i nspect the oi l pump for wear and damage.
(1) Remove the reacti on shaft support bol ts.
Fig. 75 Remove Pump Attaching Bolts
Fig. 76 Install Tool C-3752
Fig. 77 Remove Oil Pump
Fig. 78 Oil Pump Removed
(2) Remove reacti on shaft support from pump
(3) Remove the pump gears and check for wear
and damage.
(4) I nstal l the gears and check cl earances.
(5) Measure the cl earance between the outer gear
and the pump pocket (Fi g. 81). Cl earance shoul d be
0.045-0.141mm (0.0018-0.0056 i n.).
(6) Measure the cl earance between the outer gear
and the pump crescent. Cl earance shoul d be 0.020-
0.046mm (0.0008-0.0018 i n.) (Fi g. 82).
(7) Measure the cl earance between the i nner gear
and the pump crescent. Cl earance shoul d be 0.020-
0.046mm (0.0008-0.0018 i n.) (Fi g. 83).
Fig. 79 Remove Oil Pump Gasket
Fig. 80 Reaction Shaft Support
Fig. 81 Measure Outer Gear to Pocket
Fig. 82 Measure Outer Gear To Crescent
Fig. 83 Measure Inner Gear To Crescent
CAUTION: The cooler bypass valve must be
replaced if a transaxle failure has occurred. Do not
reuse old valve or attempt to clean old valve. When
installing bypass valve, insert with O-ring end
towards rear of case.
Fig. 84 Remove Bypass Valve
Fig. 85 Remove Caged Needle Bearing
Fig. 86 Remove Input Clutches Assembly
Fig. 87 No. 4 Thrust Plate
Fig. 88 Remove Front Sun Gear Assembly
NOTE: Verify that Miller Tool 5058 is centered prop-
erly to the 2/4 clutch retainer before depressing the
tool.
Fig. 89 Remove Front Carrier and Rear Annulus
Assembly
Fig. 90 Remove Rear Sun Gear
Fig. 91 Remove 2/4 Clutch Retainer Snap Ring
Fig. 92 Remove 2/4 Clutch Retainer
Fig. 93 2/4 Clutch Retainer
Fig. 94 Remove 2/4 Clutch Return Spring
NOTE: Tag 2/4 clutch pack for reassembly identifi-
cation.
Fig. 95 Remove 2/4 Clutch Pack
Fig. 96 Remove Tapered Snap Ring
Fig. 97 Remove Low/Reverse Reaction Plate
Fig. 98 Remove One Disc
Fig. 99 Remove Low/Reverse Reaction Plate Snap
Ring
Fig. 100 Remove Low/Reverse Clutch Pack
NOTE: Tag low/reverse clutch pack for reassembly
identification.
Fig. 101 Remove Rear Cover Bolts
Fig. 102 Remove Rear Cover
Fig. 103 Remove Transfer Shaft Gear Nut
Fig. 104 Transfer Shaft Gear Nut and Coned Washer
Fig. 105 Remove Transfer Shaft Gear
Fig. 106 Remove Transfer Shaft Gear and (Select)
Shim
NOTE: Screw Tool 5049-A onto transfer shaft.
Remove transfer shaft.
Fig. 107 Remove Bearing Cup Retainer
Fig. 108 Remove Transfer Gear Bearing Cone
Fig. 109 Remove Transfer Shaft Bearing Cup
Fig. 110 Remove Transfer Shaft Bearing Snap Ring
Fig. 111 Remove Transfer Shaft
Fig. 112 Bearing Cup Removed
NOTE: Remove output gear stirrup and strap bolts.
Al l transaxl es uti l i ze a sti rrup and retai ni ng strap
that i s attached to the output gear. The sti rrup pre-
vents the output gear retai ni ng bol t from turni ng
and backi ng out of the rear carri er. The strap i s used
to hol d the sti rrup to the output gear and prevent
the sti rrup retai ni ng bol ts from backi ng out.
CAUTION: When installing, be sure guide bracket
and split sleeve touch the rear of the transaxle
case.
Fig. 113 Remove Transfer Shaft Bearing Cone
Fig. 114 Loosen Stirrup Strap Bolts
Fig. 115 Remove Strap Bolts
Fig. 116 Remove Stirrup Strap
Fig. 117 Remove Stirrup
Fig. 118 Remove Output Gear Bolt
Fig. 119 Output Gear Bolt and Washer
Fig. 120 Remove Output Gear
Fig. 121 Output Gear and (Select) Shim
Fig. 122 Remove Bearing Cone
Fig. 123 Remove Rear Carrier Assembly
Fig. 124 Remove Rear Carrier Bearing Cone
Fig. 125 Low/Reverse Spring Compressor Tool
Fig. 126 Compressor Tool in Use
Fig. 127 Remove Snap Ring
Fig. 128 Low/Reverse Piston Return Spring
Fig. 129 Drive Out Anchor Shaft
Fig. 130 Remove Anchor Shaft and Plug
Fig. 131 Remove Guide Bracket Pivot Shaft
Fig. 132 Pivot Shaft and Guide Bracket
Fig. 133 Guide Bracket
Fig. 134 Guide Bracket Disassembled
Fig. 135 Remove Low/Reverse Clutch Piston
CAUTION: Drift bearing cup all the way around.
Thi s concl udes the di sassembl e of the transaxl e
centerl i ne. To di sassembl e the i nput cl utch assembl y,
refer to I nput Cl utches-Recondi ti on.
Fig. 136 Remove Piston Retainer Attaching Screws
Fig. 137 Remove Piston Retainer
Fig. 138 Remove Piston Retainer Gasket
Fig. 139 Remove Output Bearing Inner Cup
Fig. 140 Remove Output Bearing Outer Cup
INPUT CLUTCHES-RECONDITION
DISASSEMBLY
NOTE: Tag reverse clutch pack for reassembly
identification .
Fig. 141 Tapping Reaction Plate
Fig. 142 Reverse Clutch Snap Ring
Fig. 143 Pry Reverse Clutch Reaction Plate
Fig. 144 Reverse Clutch Reaction Plate
Fig. 145 Reverse Clutch Pack
Fig. 146 OD/Reverse Pressure Plate Snap Ring
NOTE: Tag overdrive clutch pack for reassembly
identification.
Fig. 147 OD/Reverse Pressure Plate
Fig. 148 Waved Snap Ring
Fig. 149 Remove OD Clutch Pack
Fig. 150 Overdrive Clutch Pack
Fig. 151 Overdrive Shaft Assembly
Fig. 152 Underdrive Shaft Assembly
NOTE: The OD/UD Reaction Plate, Snap Rings, and
Input Clutches Retainer is not interchangeable with
previous year 41TE components. The snap rings
are thicker and the position of the ring lands have
changed.
NOTE: The OD/UD clutches reaction plate has a
step on both sides. Install the OD/UD clutches reac-
tion plate tapered step side up.
NOTE: Tag underdrive clutch pack for reassembly
identification.
Fig. 153 No. 2 Needle Bearing
Fig. 154 OD/UD Reaction Plate Tapered Snap Ring
Fig. 155 OD/UD Reaction Plate
Fig. 156 Remove One UD Clutch Disc
Fig. 157 UD Clutch Flat Snap Ring
CAUTION: Compress return spring just enough to
remove or install snap ring.
Fig. 158 Underdrive Clutch Pack
Fig. 159 UD Spring Retainer Snap Ring
Fig. 160 UD Return Spring and Retainer
Fig. 161 Underdrive Clutch Piston
Fig. 162 Input Hub Tapered Snap Ring
Fig. 163 Tap on Input Hub
Fig. 164 Input Hub Removed
Fig. 165 Pull Retainer from Piston
Fig. 166 Remove Snap Ring
Fig. 167 Snap Ring and Return Spring
Fig. 168 Remove Input Shaft Snap Ring
Fig. 169 Remove Input Shaft
ASSEMBLY
Use petrol atum on al l seal s to ease assembl y of
components.
Fig. 170 Install Input Shaft
Fig. 171 Install Input Shaft Snap Ring
Fig. 172 Return Spring and Snap Ring
Fig. 173 Install Snap Ring
Fig. 174 Install OD/Reverse Piston
NOTE: The OD/UD Reaction Plate, Snap Rings, and
Input Clutches Retainer is not interchangeable with
previous year 41TE components. The snap rings
are thicker and the position of the ring lands have
changed.
Fig. 175 Install Input Shaft Hub Assembly
Fig. 176 Install Input Hub Tapered Snap Ring
Fig. 177 Underdrive Clutch Piston
Fig. 178 Seal Compressor Special Tool 5067
Fig. 179 UD Return Spring and Retainer
CAUTION: Compress return spring just enough to
remove or install snap ring.
The OD/UD cl utches reacti on pl ate has a step on
both si des. I nstal l the OD/UD cl utches reacti on pl ate
tapered step si de up.
Fig. 180 Install UD Spring Retainer and Snap Ring
Fig. 181 Underdrive Clutch Pack
Fig. 182 UD Clutch Flat Snap Ring
Fig. 183 Install Last UD Clutch Disc
Fig. 184 OD/UD Reaction Plate
Fig. 185 Tapered Snap Ring
NOTE: Snap ring ends must be located within one
finger of the input clutch hub. Be sure that snap
ring is fully seated, by pushing with screwdriver,
into snap ring groove all the way around.
Underdrive clutch pack clearance must be
0.91 to 1.47 mm (.036 to .058 inch). Sel ect the
proper reacti on pl ate to achi eve speci fi cati ons:
Fig. 186 Seating Tapered Snap Ring
Fig. 187 Set Up Dial Indicator for Clutch Clearance
Fig. 188 Use Hook Tool to Raise One Clutch Disc
UNDERDRIVE REACTION PLATE CHART
Fig. 189 Install OD Clutch Pack
Fig. 190 Install Waved Snap Ring
Fig. 191 OD/Reverse Pressure Plate
Fig. 192 Pressure Plate Installed
Fig. 193 Install Flat Snap Ring
Fig. 194 Check OD Clutch Pack Clearance
The overdrive (OD) clutch pack clearance is
1.07 to 2.44 mm (.042 to .096 inch). I f not wi thi n
speci fi cati ons, the cl utch i s not assembl ed properl y.
There i s no adjustment for the OD cl utch cl earance.
Fig. 195 Install Reverse Clutch Pack
Fig. 196 Install Reaction Plate
Fig. 197 Install Reverse Clutch Snap Ring
Fig. 198 Seating Snap Ring to Determine Reverse
Clutch Clearance
Fig. 199 Check Reverse Clutch Pack Clearance
The reverse clutch pack clearance is 0.76 to
1.24 mm (.030 to .049 inch). Sel ect the proper
reverse cl utch snap ri ng to achi eve speci fi cati ons:
Al l cl utch cl earances i n the i nput cl utch retai ner
have now been checked and approved.
To compl ete the assembl y of the i nput cl utch
retai ner, the reverse cl utch and the overdri ve cl utch
must be removed from the retai ner.
CAUTION: Do not intermix clutch parts. Keep in
exact same order.
Now proceed wi th the next phase of the assembl y:
REVERSE CLUTCH SNAP RING CHART
Fig. 200 Install No. 2 Needle Bearing
Fig. 201 Install Underdrive Shaft Assembly
Fig. 202 Install No. 3 Thrust Washer
Fig. 203 Install No. 3 Thrust Plate
Rei nstal l overdri ve cl utch and reverse cl utch as
shown. Rechecking these clutch clearances is
not necessary, as they were set and approved
previously.
TRANSAXLE ASSEMBLE
To assembl e the transaxl e centerl i ne, refer to the
fol l owi ng procedures.
Fig. 204 Install Overdrive Shaft Assembly
Fig. 205 Input Clutch Assembly
Fig. 206 Install Both Output Bearing Cups
Fig. 207 Install Piston Retainer Gasket
Fig. 208 Install Piston Retainer
Fig. 209 Install Retainer Attaching Screws
Fig. 210 Install Low/Reverse Clutch Piston
Fig. 211 Guide Bracket Disassembled
Fig. 212 Guide Bracket
Fig. 213 Pivot Shaft and Guide Bracket
Fig. 214 Install Guide Bracket Pivot Shaft
CAUTION: When installing, be sure guide bracket
and split sleeve touch the rear of the transaxle case.
Fig. 215 Install Anchor Shaft and Plug
Fig. 216 Install Low/Reverse Piston Return Spring
Fig. 217 Low/Reverse Spring Compressor Tool
Fig. 218 Compressor Tool in Use
Fig. 219 Install Snap Ring
Fig. 220 Install Rear Carrier Bearing Cone
OUTPUT GEAR BEARING ADJ USTMENT
(1) Wi th output gear removed: i nstal l a 4.50 mm
(0.177 i nch) gaugi ng shi m on the rear carri er assem-
bl y hub, usi ng grease to hol d the shi m i n pl ace.
(2) Usi ng Tool 6259, i nstal l output gear and bear-
i ng assembl y. Torque to 271 Nm (200 ft. l bs.).
To measure beari ng end pl ay:
(3) Attach Tool L-4432 to the gear.
(5) Usi ng a di al i ndi cator, mounted to the tran-
saxl e case, measure output gear end pl ay (Fi g. 223).
Fig. 221 Install Rear Carrier Assembly
Fig. 222 Install Output Gear Bearing Cone
Fig. 223 Checking Output Gear Bearings End Play
(6) Refer to the output gear beari ng shi m chart for
the requi red shi m to obtai n proper beari ng setti ng.
(7) Use Tool 6259 to remove the retai ni ng bol t and
washer. To remove the output gear, use Tool L-4407.
(8) Remove the gaugi ng shi m and i nstal l the
proper shi m (Fi g. 224). Use grease to hol d the shi m
i n pl ace. I nstal l the output gear and beari ng assem-
bl y (Fi g. 225).
OUTPUT GEAR BEARING SHIM CHART
End Play Shim Needed Part Number End Play Shim Needed
Part Num-
ber
.05mm .002 in. 4.42mm .174 in. 4412830 .53mm .021 in. 3.94mm .155 in. 4412818
.43mm .017 in. 4.02mm .158 in. 4412820 .91mm .036in. 3.54mm .139 in. 4412808
.51mm .020 in. 3.94mm .155 in. 4412818
Fig. 224 Output Gear and (Select) Shim
Fig. 225 Install Output Gear
CAUTION: Always use new retaining bolt, old
retaining bolt may not be reused.
(9) I nstal l the new retai ni ng bol t and washer (Fi g.
226). Ti ghten to 271 Nm (200 ft. l bs.) (Fi g. 227).
(10) Usi ng an i nch-pound torque wrench, check the
turni ng torque (Fi g. 228). The torque should be
between 3 and 8 inch-pounds.
I f the turni ng torque i s too hi gh, i nstal l a .04 mm
(.0016 i nch) thi cker shi m. I f the turni ng torque i s too
l ow, i nstal l a .04 mm (.0016 i nch) thi nner shi m.
Repeat unti l the proper turni ng torque i s 3 to 8 i nch
pounds.
NOTE: Install output gear stirrup and strap bolts.
Al l transaxl es uti l i ze a sti rrup and retai ni ng strap
that i s attached to the output gear. The sti rrup pre-
vents the output gear retai ni ng bol t from turni ng
and backi ng out of the rear carri er. The strap i s used
to hol d the sti rrup to the output gear and prevent
the sti rrup retai ni ng bol ts from backi ng out.
Fig. 226 Install Output Gear Bolt and Washer
Fig. 227 Tighten Output Gear to 271 Nm
(200 ft. lbs.)
Fig. 228 Check Output Gear Bearings Turning
Torque
Fig. 229 Output Gear Retaining Bolt Stirrup
(Serration Side Out)
Fig. 230 Stirrup Strap (Align Strap Holes With
Tapped Gear Holes)
Fig. 231 Install Strap Bolts
Fig. 232 Turn Stirrup Clockwise Against Flats Of
Output Gear Retaining Bolt
Fig. 233 Tighten Stirrup Strap Bolts To 23 Nm
(200 in. lbs.)
Fig. 234 Bend Tabs On Strap Up Against Flats Of
Bolts
Fig. 235 Install Transfer Shaft Bearing Cone
Fig. 236 Install Bearing Cup To Shaft
NOTE: Screw Tool 5049-A onto transfer shaft.
Install transfer shaft.
TRANSFER SHAFT BEARING
(1) I nstal l a 4.66 mm (.184 i nch) gaugi ng shi m on
the transfer shaft.
(2) I nstal l transfer shaft gear and beari ng assem-
bl y and torque the nut to 271 Nm (200 ft. l bs.).
To measure beari ng end pl ay:
Attach Tool L-4432 to the transfer gear.
Mount a steel bal l wi th grease i nto the end of
the transfer shaft.
Push and pul l the gear whi l e rotati ng back and
Usi ng a di al i ndi cator, measure transfer shaft
end pl ay.
(3) Refer to the Transfer Beari ng Shi m Chart for
the requi red shi m combi nati on to obtai n the proper
beari ng setti ng.
(4) Use Tool 6259 to remove the retai ni ng nut and
washer. Remove the transfer shaft gear usi ng Tool
L-4407.
Fig. 237 Install Transfer Shaft
Fig. 238 Install Transfer Shaft Bearing Snap Ring
Fig. 239 Install Transfer Shaft Bearing Cup Into
Retainer
Fig. 240 Install Bearing Cup Retainer
Fig. 241 Install Transfer Gear Bearing Cone
TRANSFER SHAFT BEARING SHIM CHART
End Play Shim Needed Part Number End Play Shim Needed Part Number
.30mm .012 in. 4.38mm .172 in. 4412829 1.02mm .040 in. 3.66mm .144 in. 4412811
.71mm .028 in. 3.98mm .157 in. 4412819 1.45mm .057 in 3.26mm .128 in. 4412801
(5) Remove the gaugi ng shi m and i nstal l the cor-
rect shi m (Fi g. 242). I nstal l the transfer gear and
beari ng assembl y (Fi g. 243).
CAUTION: Original retaining nut may not be
reused. Always use a new retaining nut when reas-
sembling.
(6) I nstal l the new retai ni ng nut and washer and
torque to 271 Nm (200 ft. l bs.) (Fi g. 244). Measure
transfer shaft end play, end play should be .05
to .10 mm (.002 to .004 inch).
(7) Measure beari ng end pl ay as outl i ned i n . End
pl ay shoul d be between .05 mm and .10 mm (.002 to
.004 i nch).
NOTE: If end play is too high, install a .04 mm
(.0016 inch) thinner shim. If end play is too low,
install a .04 mm (.0016 inch) thicker shim combina-
tion. Repeat until .05 to .10 mm (.002 to .004 inch)
end play is obtained.
NOTE: Install the low/reverse reaction plate
stepped side up.
Fig. 242 Transfer Shaft Gear and (Select) Shim
Fig. 243 Install Transfer Shaft Gear
Fig. 244 Tighten Nut to 271 Nm (200 ft. lbs.)
Fig. 245 Install Rear Cover
Fig. 246 Install Rear Cover Bolts
Fig. 247 Install Low/Reverse Clutch Pack
Fig. 248 Install Low/Reverse Reaction Plate Snap
Ring
Fig. 249 Install One Disc
Fig. 250 Tapered Snap Ring Instructions
Fig. 251 Snap Ring Installed
Press down cl utch pack wi th fi nger and zero di al
i ndi cator. Low/Reverse clutch pack clearance is
0.89 to 1.04 (.035 to .042 inch).
Sel ect the proper l ow/reverse reacti on pl ate to
achi eve speci fi cati ons:
NOTE: When installing the 2-4 clutch plates and
discs, the orientation should be alternated so the
pilot pads of adjacent plates do not align, refer to
(Fig. 254).
Fig. 252 Check Low/Reverse Clutch Clearance
LOW/REVERSE REACTION PLATE CHART
PART NUMBER THICKNESS
4567893 6.92mm (.273 in.)
4567899 6.66mm (.262 in.)
4567898 6.40mm (.252 in.)
4567897 6.14mm (.242 in.)
4567896 5.88mm (.232 in.)
4567895 5.62mm (.221 in.)
4567894 5.36mm (.211 in.)
Fig. 253 Install 2/4 Clutch Pack
Fig. 254 Stagger 2/4 Clutch Plate Pads
Fig. 255 Install 2/4 Clutch Return Spring
Fig. 256 Proper Orientation of 2/4 Clutch Retainer
and Spring
NOTE: Verify that Miller Tool 5058 is centered prop-
erly to the 2/4 clutch retainer before depressing the
tool.
Press down cl utch pack wi th fi nger and zero di al
i ndi cator. The 2/4 clutch pack clearance is 0.76 to
2.64mm (.030 to .104 inch). I f not wi thi n speci fi ca-
ti ons, the cl utch i s not assembl ed properl y. There is
no adjustment for the 2/4 clutch clearance.
DETERMINING No. 4 THRUST PLATE
THICKNESSINPUT SHAFT END PLAY
To determi ne the proper thi ckness of the No. 4
thrust pl ate, sel ect the thi nnest No. 4 thrust pl ate.
Usi ng petrol atum (Fi g. 263) to hol d thrust pl ate i n
posi ti on, i nstal l i nput cl utch assembl y. Be sure the
i nput cl utch assembl y i s compl etel y seated (Fi g. 264).
CAUTION: If view through input speed sensor hole
is not as shown above, the input clutches assembly
is not seated properly.
Remove the oi l pump O-ri ng (Fi g. 265). You wi l l be
abl e to i nstal l and remove the oi l pump and gasket
very easi l y to sel ect the proper No. 4 thrust pl ate.
Fig. 257 Install 2/4 Clutch Retainer
Fig. 258 Install 2/4 Clutch Retainer Snap Ring
Fig. 259 Check 2/4 Clutch Clearance
Fig. 260 Install Rear Sun Gear
Fig. 261 Install Front Carrier and Rear Annulus
Assembly
NOTE: Use screw-in dowels or phillips-head screw-
drivers to align pump to case.
CAUTION: Be sure to reinstall O-ring on oil pump
after selecting the proper No. 4 thrust plate.
Measure the i nput shaft end pl ay wi th the tran-
saxl e i n the verti cal posi ti on. Thi s wi l l ensure that
the measurement wi l l be accurate.
NOTE: Input shaft end play must be .005 to .025
inch.
For exampl e, i f end pl ay readi ng i s .055 i nch, sel ect
No. 4 Thrust Pl ate whi ch i s .071 to .074 thi ck. Thi s
shoul d provi de an i nput shaft end pl ay readi ng of
.020 i nch whi ch i s wi thi n speci fi cati ons.
Fig. 262 Install Front Sun Gear Assembly
Fig. 263 Select Thinnest No. 4 Thrust Plate
Fig. 264 View Through Input Speed Sensor Hole
Fig. 265 Remove Oil Pump O-Ring
See chart to sel ect the proper No. 4 thrust pl ate.
Rei nstal l the i nput cl utches assembl y wi th the
sel ected thrust pl ate .
CAUTION: The cooler bypass valve must be
replaced if a transaxle failure has occurred. Do not
reuse old valve or attempt to clean old valve. When
installing bypass valve, insert with O-ring end
towards rear of case.
NO. 4 THRUST PLATE CHART
PART NUMBER THICKNESS
4431662 .91mm (.036 in.)
4431663 1.14mm (.045 in.)
4431664 1.37mm (.054 in.)
4431665 1.60mm (.063 in.)
3836237 1.73mm (.068 in.)
4431666 1.80mm (.071 in.)
3836238 1.96mm (.077 in.)
4431667 2.03mm (.080 in.)
3836239 2.16mm (.085 in.)
4431668 2.24mm (.088 in.)
3836240 2.39mm (.094 in.)
4431669 2.46mm (.097 in.)
3836241 2.62mm (.103 in.)
4446670 2.67mm (.105 in.)
4446671 2.90mm (.114 in.)
4446672 3.15mm (.124 in.)
4446601 3.38mm (.133 in.)
Fig. 267 Install Input Clutches Assembly
Fig. 268 Install Caged Needle Bearing
Fig. 269 Install Bypass Valve
Fig. 270 Install Oil Pump Gasket
NOTE: Dependent on engine application, some
accumulators will have two springs and others will
have one spring. The springs are color coded for
application and year.
NOTE: To ease installation of the valve body, turn
the manual valve fully clockwise.
Fig. 271 Install Oil Pump
Fig. 272 Install Pump Attaching Bolts
Fig. 273 Install Low/Reverse Accumulator
Fig. 274 Install Low/Reverse Accumulator Plug
(Cover)
Fig. 275 Install Low/Reverse Accumulator Snap
Ring
Fig. 276 Accumulator (Underdrive)
CAUTION: Do not handle the valve body from the
manual valve. Damage could result.
Fig. 277 Accumulator (Overdrive)
Fig. 278 Install Accumulators
Fig. 279 Install Valve Body
Fig. 280 Install Valve Body Attaching Bolts
Fig. 281 Install Oil Filter
Fig. 282 Install Oil Pan
(1) I nstal l transaxl e sol enoi d pack (Fi g. 284).
(2) I nstal l i nput and output speed sensors.
Thi s concl udes the assembl y of the transaxl e cen-
terl i ne.
DIFFERENTIAL REPAIR
NOTE: The differential is serviced as an assembly.
The only parts that are serviceable within the differ-
ential are the differential bearing cups and cones. If
any other part fails within the differential, you must
replace the differential assembly along with the
transfer shaft.
DISASSEMBLE
The transfer shaft shoul d be removed for di fferen-
ti al repai r and beari ng turni ng torque checki ng.
(1) Remove the di fferenti al cover and bol ts (Fi g.
285) (Fi g. 286).
(2) Remove the di fferenti al beari ng retai ner and
bol ts (Fi g. 287) (Fi g. 288).
(3) Usi ng a pl asti c hammer, remove extensi on
housi ng/adapter pl ate on the ri ght si de of the tran-
saxl e.
Fig. 283 Install Pan Bolts
Fig. 284 Install Solenoid Pack
Fig. 285 Differential Cover Bolts
Fig. 286 Remove Differential Cover
Fig. 287 Differential Retainer Bolts
WARNING: HOLD ONTO DIFFERENTIAL ASSEMBLY
TO PREVENT IT FROM ROLLING OUT OF HOUSING.
(4) Use Mi l l er Speci al Tool 5048, 5048-3 Col l ets,
and L-4539-2 Button to remove the di fferenti al bear-
i ng cone on the extensi on housi ng si de.
(5) Use Mi l l er Speci al Tool 5048, 5048-4 Col l ets,
and L-4539-2 Button to remove the di fferenti al bear-
i ng cone on the beari ng retai ner si de (Fi g. 289) (Fi g.
290) (Fi g. 291).
(6) Usi ng Mi l l er Speci al Tool L-4518, remove the
di fferenti al beari ng race from the extensi on housi ng.
(7) Usi ng Mi l l er Speci al Tool 6062A, remove the
di fferenti al beari ng race from the beari ng retai ner
(Fi g. 292) (Fi g. 293).
Fig. 288 Remove Bearing Retainer
Fig. 289 Position Button and Collets Onto
Differential and Bearing (Ring Gear Side)
Fig. 290 Position Tool 5048 Over Button and Collets
at Differential Bearing (Ring Gear Side)
Fig. 291 Remove Differential Bearing Cone (Ring
Gear Side)
Fig. 292 Position Bearing Cup Remover Tool in
Retainer
CHECKING SIDE GEAR END PLAY
Check si de gear end pl ay whenever the di fferenti al
i s removed for servi ce.
NOTE: Side gear end play must be BETWEEN 0.001
to 0.013 inch.
ASSEMBLE
NOTE: Use Mopar Silicone Rubber Adhesive Seal-
ant, or equivalent, on retainer and extension hous-
ing/adapter plate to seal to case.
(1) Usi ng Mi l l er Speci al Tool L-4410, and C-4171,
i nstal l di fferenti al beari ng to di fferenti al (extensi on
housi ng si de) (Fi g. 296).
Fig. 293 Remove Bearing Cup
DIFFERENTIAL SERVICE TOOLS
COMPONENT REMOVER INSTALLER
Diff. Bear. On
Retainer Side
5048, 5048-4
Collets,
L-4539-2
Button
5052, C-4171
Diff. Bear. On
Ext. Hous. Side
5048, 5048-3
Collets,
L-4539-2
Button
L-4410, C-4171
Diff. Race. On
Retainer Side
6062-A 6061, C-4171
Diff. Race. On
Ext. Hous. Side
L-4518 L-4520, C-4171
Extension
Housing Seal
7794-A, C-637
Slide Hammer
L-4520, C-4171
Bearing
Retainer Seal
794-A, C-637
Slide Hammer
L-4520, C-4171
Fig. 294 Checking Side Gear End Play (Extension
Housing Side)
Fig. 295 Checking Side Gear End Play (Bearing
Retainer Side)
Fig. 296 Position Bearing Cone Onto Differential
(2) Usi ng Mi l l er Speci al Tool 5052 and C-4171,
i nstal l di fferenti al beari ng to di fferenti al (beari ng
retai ner si de).
(3) Usi ng Mi l l er Speci al Tool 6061 and C-4171,
i nstal l di fferenti al beari ng race to beari ng retai ner
(Fi g. 297).
(4) Usi ng Mi l l er Speci al Tool L4520 and C-4171,
i nstal l di fferenti al beari ng to extensi on housi ng.
DIFFERENTIAL BEARING PRELOAD
ADJ USTMENT
NOTE: Perform all differential bearing preload mea-
surements with the transfer shaft and gear
removed.
DIFFERENTIAL BEARING PRELOAD ADJUSTMENT USING
EXISTING SHIM
the support stand, di fferenti al beari ng retai ner si de
up.
(2) I nstal l Tool L-4436A i nto the di fferenti al and
onto the pi ni on mate shaft (Fi g. 298).
seated.
wrench, check the turni ng torque of the di fferenti al
(Fi g. 299). The turning torque should be
(5) I f the turni ng torque i s wi thi n speci fi cati ons,
remove tool s. Setup i s compl ete.
(6) I f turni ng torque i s not wi thi n speci fi cati ons
proceed wi th the fol l owi ng steps.
(a) Remove di fferenti al beari ng retai ner from
(b) Remove the beari ng cup from the di fferenti al
beari ng retai ner usi ng Tool 6062A.
(c) Remove the exi sti ng shi m from under the
cup.
(d) Measure the exi sti ng shi m.
NOTE: If the turning torque was too high when
measured, install a .05 mm (.002 inch) thinner shim.
If the turning torque is was too low, install a .05 mm
(.002 inch) thicker shim. Repeat until 5 to 18 inch-
pounds turning torque is obtained.
Oil Baffle is not required to be installed when
making shim selection.
(e) I nstal l the proper shi m under the beari ng
cup. Make sure the oi l baffl e i s i nstal l ed properl y
i n the beari ng retai ner, bel ow the beari ng shi m
and cup.
(f) I nstal l the di fferenti al beari ng retai ner usi ng
Tool 5052 and C-4171. Seal the retai ner to the
housi ng wi th MOPAR Adhesi ve Seal ant and
torque bol ts to 28 Nm (250 i n. l bs.).
Fig. 298 Tool L-4436 and Torque Wrench
Fig. 299 Checking Differential Bearings Turning
Torque
wrench, recheck the turni ng torque of the di fferenti al
(Fi g. 299). The turning torque should be
Transaxl e case
Di fferenti al carri er
Di fferenti al beari ng retai ner
Extensi on housi ng
Di fferenti al beari ng cups and cones
PRELOAD ADJUSTMENT W/O SHIM
(1) Remove the beari ng cup from the di fferenti al
beari ng retai ner usi ng Mi l l er speci al Tool 6062A.
(2) Remove exi sti ng shi m from under beari ng cup.
(3) Rei nstal l the beari ng cup i nto the retai ner
usi ng Mi l l er Speci al Tool 6061, and C-4171.
NOTE: Oil baffle is not required when making the
shim calculation.
(4) I nstal l the beari ng retai ner i nto the case.
Torque bol ts to 28 Nm (250 i n. l bs.).
the support stand and i nstal l Mi l l er Speci al Tool
L-4436-A i nto the beari ng retai ner.
seated.
(7) Attach a di al i ndi cator to the case and zero the
di al . Pl ace the ti p on the end of Speci al Tool
L-4436-A.
(8) Pl ace a l arge screwdri ver to each si de of the
ri ng gear and l i ft. Check the di al i ndi cator for the
amount of end pl ay.
CAUTION: Do not damage the transaxle case
and/or differential retainer sealing surface.
(9) Usi ng the end pl ay measurement that was
determi ned, add .18mm (.007 i nch). Thi s shoul d gi ve
you between 5 and 18 i nch pounds of beari ng pre-
l oad. Refer to the Di fferenti al Beari ng Shi m Chart to
determi ne whi ch shi m to use.
(10) Remove the di fferenti al beari ng retai ner.
Remove the beari ng cup.
DIFFERENTIAL BEARING SHIM CHART
PART NUMBER SHIM THICKNESS
MM INCH
4659257 .980 0.0386
4659258 1.02 0.0402
4659259 1.06 0.0418
4659260 1.10 0.0434
4659261 1.14 0.0449
4659262 1.18 0.0465
4659263 1.22 0.0481
4659264 1.26 0.0497
4659265 1.30 0.0512
4659266 1.34 0.0528
4659267 1.38 0.0544
4659268 1.42 0.0560
4659269 1.46 0.0575
4659270 1.50 0.0591
4659271 1.54 0.0607
4659272 1.58 0.0623
4659273 1.62 0.0638
4659274 1.66 0.0654
4659275 1.70 0.0670
4659283 2.02 0.0796
4659284 2.06 0.0812
(11) I nstal l the oi l baffl e. I nstal l the proper shi m
combi nati on under the beari ng cup.
(12) I nstal l the di fferenti al beari ng retai ner. Seal
the retai ner to the housi ng wi th Mopar Si l i cone
Rubber Adhesi ve Seal ant. Torque bol ts to 28 Nm
(250 i n. l bs.).
(13) Usi ng Mi l l er Speci al Tool L-4436-A and an
i nch-pound torque wrench, check the turni ng torque
of the di fferenti al (Fi g. 299). The turni ng torque
shoul d be between 5-18 i nch-pounds.
NOTE: If turning torque is too high install a .05mm
(.002 inch) thicker shim. If the turning torque is too
low, install a .05mm (.002 inch) thinner shim. Repeat
until 5-18 inch-pounds of turning torque is
obtained.
CLEANING VALVE BODY
Pri or to removi ng any transaxl e parts, pl ug al l
openi ngs and cl ean uni t, preferabl y by steam. Cl ean-
l i ness through enti re di sassembl y and assembl y can-
not be overemphasi zed. When di sassembl i ng, each
part shoul d be washed i n a sui tabl e sol vent, then
dri ed by compressed ai r. Do not wipe parts with
shop towels. Al l mati ng surfaces i n the transaxl es
are accuratel y machi ned; therefore, careful handl i ng
of al l parts must be exerci sed to avoi d ni cks or burrs.
NOTE: Tag all springs, as they are removed, for
reassembly identification.
ADJ USTMENTS
GEARSHIFT CABLE ADJUSTMENT
posi ti on.
parki ng brake.
adjusted.
cedure.
Fig. 300 Gearshift Cable Adjustment
41TE TRANSAXLE HYDRAULIC SCHEMATICS
4
1
T
E
T
R
A
N
S
A
X
L
E
H
Y
D
R
A
U
L
I
C
S
C
H
E
M
A
T
I
C
4
1
T
E
T
R
A
N
S
A
X
L
E
H
Y
D
R
A
U
L
I
C
S
C
H
E
M
A
T
I
C
4
1
T
E
T
R
A
N
S
A
X
L
E
H
Y
D
R
A
U
L
I
C
S
C
H
E
M
A
T
I
C
4
1
T
E
T
R
A
N
S
A
X
L
E
H
Y
D
R
A
U
L
I
C
S
C
H
E
M
A
T
I
C
4
1
T
E
T
R
A
N
S
A
X
L
E
H
Y
D
R
A
U
L
I
C
S
C
H
E
M
A
T
I
C
4
1
T
E
T
R
A
N
S
A
X
L
E
H
Y
D
R
A
U
L
I
C
S
C
H
E
M
A
T
I
C
4
1
T
E
T
R
A
N
S
A
X
L
E
H
Y
D
R
A
U
L
I
C
S
C
H
E
M
A
T
I
C
4
1
T
E
T
R
A
N
S
A
X
L
E
H
Y
D
R
A
U
L
I
C
S
C
H
E
M
A
T
I
C
4
1
T
E
T
R
A
N
S
A
X
L
E
H
Y
D
R
A
U
L
I
C
S
C
H
E
M
A
T
I
C
4
1
T
E
T
R
A
N
S
A
X
L
E
H
Y
D
R
A
U
L
I
C
S
C
H
E
M
A
T
I
C
4
1
T
E
T
R
A
N
S
A
X
L
E
H
Y
D
R
A
U
L
I
C
S
C
H
E
M
A
T
I
C
4
1
T
E
T
R
A
N
S
A
X
L
E
H
Y
D
R
A
U
L
I
C
S
C
H
E
M
A
T
I
C
4
1
T
E
T
R
A
N
S
A
X
L
E
H
Y
D
R
A
U
L
I
C
S
C
H
E
M
A
T
I
C
SPECIFICATIONS
Type . . . . . . . . . . . . . . . . . . . . . . . . . .Ful l y adapti ve,
el ectroni cal l y control l ed,
four speed automati c wi th
torque converter
and i ntegral di fferenti al
Torque Converter Di ameter . . . . . . . .241 mi l l i meters
(9.48 i n.)
Oi l Capaci ty . . . . . . . . . . . . . . . . . . . . . . . .8.6 Li ters
(18.25 pi nts)
Oi l Type. . . . . . . . . . .Mopar ATF PLUS 3Type 7176
Cool i ng Method . . . . . . . . . . .Water Heat Exchanger
and/or ai r to oi l
heat exchanger
Lubri cati on . . . . . .Pump (i nternal -external gear-type
Gear Ratios
Transmission Portion
Fi rst Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.84
Second Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.57
Di rect Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.00
Overdri ve Gear . . . . . . . . . . . . . . . . . . . . . . . . . .0.69
Reverse Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.21
Overall Top Gear Ratio
3.8 Li ter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.38
3.3 Li ter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.49
2.4 Li ter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.69
Pump Clearances
Outer Gear To Pocket . . . . . . . . . . . . .0.045-0.141mm
(0.0018-0.0056 i n.)
Outer Gear Si de Cl earance. . . . . . . . .0.020-0.046mm
(0.0008-0.0018 i n.)
I nner Gear Si de Cl earance . . . . . . . . .0.020-0.046mm
(0.0008-0.0018 i n.)
Tapered Roller Bearing Settings
Di fferenti al Assembl y . . .5 to 18 i n. l bs. Drag Torque
Output Hub. . . . . . . . . . . .3 to 8 i n. l bs. Drag Torque
Transfer Shaft . . . . . . . . .0.002 to 0.004 i n. End Pl ay
Overal l Drag At Output Hub . . . . . . . .3 to 16 i n. l bs.
Drag Torque
Clutch Pack Clearances
Low/Rev Cl utch
(Sel ect Reacti on Pl ate) . . . . . . . . . . . .0.89-1.04mm
(0.035-0.042 i n.)
Two/Four Cl utch
(No Sel ecti on). . . . . . . . . . . . . . . . . . .0.76-2.64mm
(0.030-0.104 i n.)
Reverse Cl utch (Sel ect Snap Ri ng). . . . .0.76-1.24mm
(0.030-0.049 i n.)
Overdri ve Cl utch
(No Sel ecti on). . . . . . . . . . . . . . . . . . .0.96-2.26mm
(0.038-0.089 i n.)
Underdri ve Cl utch
Sel ect Pressure Pl ate) . . . . . . . . . . . .0.91-1.47mm
(0.036-0.058 i n.)
Transmi ssi on End Pl ay . . . . . . . . . . . . .0.12-0.63mm
(0.005-0.025 i n.)
41TE TORQUE SPECIFICATIONS
DESCRIPTION TORQUE
Cool er Li ne Fi tti ngs . . . . . . . . . .12 Nm (105 i n. l bs.)
Di fferenti al Cover . . . . . . . . . . . .19 Nm (165 i n. l bs.)
Di fferenti al Ri ng Gear . . . . . . . . .95 Nm (70 ft. l bs.)
Di fferenti al Beari ng Ret. . . . . . . .28 Nm (21 ft. l bs.)
Dri vepl ate To Crank. Bol ts . . . . . .95 Nm (70 ft. l bs.)
Dri vepl ate To Torque Conv. . . . . . .75 Nm (55 ft. l bs.)
Ei ght Way Sol enoi d Conn. . . . . . . .4 Nm (35 i n. l bs.)
Extensi on Housi ng . . . . . . . . . . . .28 Nm (21 ft. l bs.)
I nput Speed Sensor . . . . . . . . . . . .27 Nm (20 ft. l bs.)
L/R Cl utch Retai ner . . . . . . . . . . . .5 Nm (45 i n. l bs.)
Oi l Pan To Trans. Case. . . . . . . .19 Nm (165 i n. l bs.)
Output Gear Bol t . . . . . . . . . . .271 Nm (200 ft. l bs.)
Output Gear Sti rrup Ret. . . . . . . .23 Nm (17 ft. l bs.)
Output Speed Sensor . . . . . . . . . .27 Nm (20 ft. l bs.)
Pressure Taps . . . . . . . . . . . . . . . .5 Nm (45 i n. l bs.)
Pump To Case Bol ts . . . . . . . . . . .27 Nm (20 ft. l bs.)
Reacti on Shaft Bol ts . . . . . . . . . . .27 Nm (20 ft. l bs.)
Rear End Cover . . . . . . . . . . . . . .19 Nm (14 ft. l bs.)
Si xty-Way Connector . . . . . . . . . . .4 Nm (35 i n. l bs.)
Sol enoi d Assembl y To Case. . . . .12 Nm (105 i n. l bs.)
Transmi ssi on Range Sensor . . . . . .5 Nm (45 i n. l bs.)
Transfer Gear Nut . . . . . . . . . .271 Nm (200 ft. l bs.)
Transfer Pl ate To Case . . . . . . . .12 Nm (105 i n. l bs.)
Val ve Body To Case Bol ts . . . . . .12 Nm (105 i n. l bs.)
Val ve Body Bol ts . . . . . . . . . . . . . .5 Nm (45 i n. l bs.)
Vent Assembl y . . . . . . . . . . . . . .12 Nm (105 i n. l bs.)
SPECIAL TOOLS
Puller C-637
Pressure Gauge (Low) C-3292
Pressure Gauge (High) C-3293SP
Oil Pump Puller C-3752
Seal Puller C-3981B
Universal Handle C-4171
Seal Installer C-4193A
Adapter C-4996
Remover Kit L-4406
Gear Puller L-4407A
Gear Checking Plate L-4432
Bearing Puller L-4435
Differential Tool L-4436A
Special Jaw Set L-4518
Installer L-4520
Thrust Button L-4539-2
Bearing Splitter P-334
Puller Set 5048
Remover/Installer 5049-A
Installer 5050A
Installer 5052
Compressor 5058A
Compressor 5059-A
Installer 5067
Pliers 6051
Installer 6052
Installer 6053
Button 6055
Plate 6056
Disk 6057
Installer 6061
Remover 6062-A
Holder 6259
Bolt 6260
Installer 6261
Tip 6268
Remover/Installer 6301
Remover/Installer 6302
Installer 6536-A
Cooler Flusher 6906A
Puller 7794-A
POWER TRANSFER UNIT
INDEX
page page
GENERAL INFORMATION
POWER TRANSFER UNIT . . . . . . . . . . . . . . . . 165
FLUID LEAK DIAGNOSIS . . . . . . . . . . . . . . . . . 167
SEAL IDENTIFICATION . . . . . . . . . . . . . . . . . . . 165
DIFFERENTIAL CARRIER SEAL . . . . . . . . . . . . 170
END COVER BALL BEARING . . . . . . . . . . . . . . 178
END COVER SEAL . . . . . . . . . . . . . . . . . . . . . . 169
HALF SHAFT INNER SEAL . . . . . . . . . . . . . . . . 175
INPUT SHAFT COVER SEAL . . . . . . . . . . . . . . 174
INPUT SHAFT END SEAL . . . . . . . . . . . . . . . . . 177
INPUT SHAFT SEAL . . . . . . . . . . . . . . . . . . . . . 169
OUTER HALF SHAFT SEAL . . . . . . . . . . . . . . . 177
POWER TRANSFER UNIT (P.T.U.) . . . . . . . . . . 167
POWER TRANSFER UNIT OUTPUT SEAL . . . . 171
REAR COVER O-RING . . . . . . . . . . . . . . . . . . . 171
ADJUSTMENTS
OUTPUT FLANGE SHIM SELECTION . . . . . . . . 180
SPECIFICATIONS
TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
SPECIAL TOOLS
SDP POWER TRANSFER UNIT . . . . . . . . . . . . 181
GENERAL INFORMATION
POWER TRANSFER UNIT
The Power Transfer Uni t (P.T.U.) i s attached to a
modi fi ed automati c transaxl e case where the ri ght
hal f shaft extensi on housi ng woul d normal l y be
l ocated. The Transfer Uni t provi des the power to the
rear wheel s through a hypoi d ri ng gear and pi ni on
set.
The Power Transfer Uni t i s seal ed from the tran-
saxl e and has i ts own oi l sump. The Uni t uses SAE
85W-90 gear l ubri cant and hol ds 1.15 l i ters (1.22
quarts).
The Power Transfer Uni t fi l l pl ug i s l ocated on the
end cover (Fi g. 1). Do not mistake the black plas-
tic inspection plug located on the P.T.U. case
for the fill plug.
Servi ce of the Power Transfer Uni t i s l i mi ted to:
Seal s
Gaskets
One bal l beari ng
Output fl ange
I f the ri ng gear and pi ni on, any tapered rol l er
beari ngs, case, covers, or pi ni on carri er fai l the enti re
uni t must be repl aced.
SEAL IDENTIFICATION
For accurate seal di agnosi s, repai r seal name and
l ocati on i s cri ti cal . Refer to (Fi g. 2), (Fi g. 3), (Fi g. 4)
and (Fi g. 5) for correct seal name and l ocati on.
Fig. 1 Fill Plug Location
Fig. 2 Seal Location
P
o
w
e
r
T
r
a
n
s
f
e
r
U
n
i
t
C
o
m
p
o
n
e
n
t
s
FLUID LEAK DIAGNOSIS
When di agnosi ng fl ui d l eaks on the Power Transfer
Uni t two weep hol es are provi ded to di agnose certai n
seal l eaks. These hol es are l ocated on the bottom si de
of the assembl y (Fi g. 6).
I f fl ui d l eak i s detected from ei ther weep hol e, seal
repl acement i s necessary. Do not attempt to repair
the leak by sealing weep holes, they must be kept
cl ear of seal ants for proper seal operati on.
I f fl ui d i s l eaki ng from weep hol e A (Fi g. 6) the
type of fl ui d l eaki ng wi l l determi ne whi ch seal needs
to be repl aced. I f the fl ui d l eaki ng i s red i n col or
(transmi ssi on fl ui d) thi s i ndi cates that the Transmi s-
si on di fferenti al carri er seal shoul d be repl aced. I f
the fl ui d l eaki ng i s l i ght brown (gear l ube) thi s i ndi -
cates that the Power Transfer Uni t i nput seal shoul d
be repl aced. For repl acement of these seal s refer to
Power Transfer Uni t Servi ce Procedures.
I f fl ui d i s l eaki ng from weep hol e B (Fi g. 6) the
type of fl ui d l eaki ng wi l l determi ne whi ch seal i s
l eaki ng. I f the fl ui d l eaki ng i s red i n col or (transmi s-
si on fl ui d) thi s i ndi cates that the i nput shaft end seal
shoul d be repl aced. I f the fl ui d l eaki ng i s l i ght brown
(gear l ube) thi s i ndi cates that the hal f shaft i nner
seal and P.T.U. i nput shaft cover seal shoul d be
repl aced. For repl acement of these seal s refer to
Power Transfer Uni t Servi ce Procedures.
Before condemni ng any seal or gasket be sure that
the rear rocker arm cover on the engi ne i s not the
cause of the oi l l eak. Oi l l eaki ng from the rocker arm
cover i s easi l y mi staken for a l eaki ng Power Transfer
Uni t.
POWER TRANSFER UNIT (P. T. U. )
REMOVAL
(1) Rai se vehi cl e and remove front wheel s.
Fig. 6 Weep Hole Locations
CAUTION: A certain amount of oil will drain out of
the transaxle when the drive shaft is removed.
(2) Remove ri ght front dri ve shaft. I nstal l a pl ug
i nto the ri ght dri veshaft seal hol e. Refer to Group 2,
Suspensi on to remove or i nstal l wheel hub nut and
ri ght dri ve shaft.
(3) Mark propel l er shaft front fl ange.
(4) Separate propel l er shaft from P.T.U. assembl y
(Fi g. 7).
CAUTION: Do not let propeller shaft to hang freely.
Damage to the shaft will occur.
(5) Suspend propel l er shaft from underbody of
vehi cl e.
(6) Remove cradl e pl ate (Fi g. 8).
(7) Remove the Power Transfer Uni t mounti ng
bracket bol ts at the rear of the uni t (Fi g. 9).
(8) Remove the ri ght outboard support bracket and
bol ts near the ri ght axl e shaft.
(9) Remove the four mounti ng bol ts for the P.T.U.
(Fi g. 10) and (Fi g. 11).
(10) Remove P.T.U. assembl y from vehi cl e.
Fig. 7 Driveshaft Flange
Fig. 8 Cradle Plate
Fig. 9 Remove Rear P.T.U Bracket Bolts
Fig. 10 P.T.U. Lower Mounting Bolts
Fig. 11 P.T.U. Upper Mounting Bolts
INSTALLATION
(1) To i nstal l , reverse removal procedure. Check
transaxl e fl ui d and P.T.U. fl ui d and fi l l to l evel .
(2) Refer to the Speci fi cati ons secti on for the
proper torque speci fi cati ons.
END COVER SEAL
The Power Transfer Uni t must be removed from
the vehi cl e to perform thi s operati on. Refer to Power
Transfer Uni t Removal i n thi s secti on for procedures.
(1) Remove P.T.U. end cover bol ts (Fi g. 12).
(2) Gentl y tap on end cover ears wi th a hammer to
separate end cover from the case (Fi g. 13).
(3) Cl ean and i nspect seal er surfaces.
(4) Appl y Mopar Gasket Maker, Locti te Gasket
El i mi nator No.518 or equi val ent to seal i ng surfaces.
(5) Rei nstal l cover and ti ghten bol ts to 28 Nm
(250 i n. l bs.) i n the sequence shown i n (Fi g. 14).
Reti ghten fi rst bol t after al l others are ti ght.
CAUTION: When end cover is installed be careful
not to damage the P.T.U. Input Shaft Cover Seal.
(6) Rei nstal l P.T.U. i nto vehi cl e.
(7) Check and fi l l fl ui ds as requi red.
INPUT SHAFT SEAL
the vehi cl e to servi ce thi s seal . Refer to Power Trans-
fer Uni t Removal i n thi s secti on for procedures.
REMOVAL
(2) Gentl y tap on end cover ears to separate cover
from case (Fi g. 16).
(3) Remove ri ng gear oi l trough (Fi g. 17).
(4) Remove i nput shaft and ri ng gear from case
(Fi g. 18).
(5) Use Speci al Tool No. 7794-A (seal pul l er) to
remove seal (Fi g. 19).
Fig. 12 P.T.U. End Cover Bolts
Fig. 13 End Cover Removal
Fig. 14 Bolt Tightening Sequence
INSTALLATION
(1) Cl ean and i nspect seal area.
(2) Lay housi ng on bench and i nstal l new seal wi th
seal dri ver C-4657 and handl e C-4171 (Fi g. 20). The
seal must be i nstal l ed wi th the spri ng si de faci ng
towards the ri ng gear. Dri ve the seal i n unti l i t bot-
toms agai nst the case shoul der.
(3) I nstal l i nput shaft.
(4) I nstal l oi l trough.
(5) Appl y Mopar Gasket Maker or equi val ent to
seal i ng surfaces of end cover and rei nstal l . Ti ghten
(6) Rei nstal l P.T.U. assembl y i nto vehi cl e.
DIFFERENTIAL CARRIER SEAL
the vehi cl e to repl ace thi s seal .
REMOVAL
(1) Remove P.T.U. from vehi cl e.
Fig. 17 Oil Trough
Fig. 18 Input Shaft and Ring Gear Removal
(2) Use a pry bar to remove seal from retai ner
pl ate (Fi g. 21). Be careful not to damage seal journal
when removi ng seal .
INSTALLATION
(1) Usi ng a l arge socket, careful l y i nstal l new seal .
The spri ng si de of the seal must face the transaxl e
di fferenti al .
(2) Rei nstal l the P.T.U. i nto the vehi cl e.
REAR COVER O-RING
REMOVAL
(2) Remove rear cover retai ni ng bol ts (Fi g. 22).
(3) I ndex rear cover to the case for l ater reassem-
bl y (Fi g. 23).
(4) Pul l rear cover out of the P.T.U. case (Fi g. 24).
(5) Remove rear cover O-Ri ng (Fi g. 25).
INSTALLATION
POWER TRANSFER UNIT OUTPUT SEAL
The power transfer uni t must be removed from the
vehi cl e to repl ace thi s seal .
Fig. 19 Seal Removal
Fig. 20 Seal Installation
Fig. 21 Transaxle Differential Carrier Seal
REMOVAL
(2) Remove propel l er shaft.
(3) Remove rear cover retai ni ng bol ts (Fi g. 26).
(4) I ndex rear cover to the case for l ater reassem-
bl y (Fi g. 27).
(5) Pul l rear cover out of the P.T.U. case (Fi g. 28).
Fig. 23 Mark Rear Cover
Fig. 24 Rear Cover Removal
Fig. 25 O-Ring Removal
Fig. 27 Mark Rear Cover
Fig. 28 Rear Cover Removal
(6) Remove output fl ange nut (Fi g. 29).
(7) I ndex the pi ni on to the fl ange (Fi g. 30).
(8) Usi ng a hydraul i c press, press off output fl ange
from pi ni on.
(9) Use a hammer and chi sel to remove output
seal (Fi g. 31).
CAUTION: If the output flange requires replace-
ment, a new shim may be required. Refer to Output
Flange Shim Selection procedure in this section to
determine correct shim requirements.
INSTALLATION
(1) I nstal l new seal wi th Seal I nstal l er 5049 (Fi g.
32).
(2) I f the ori gi nal fl ange i s used, al i gn i ndex marks
and press fl ange onto pi ni on. I f a new fl ange i s used
di sregard the al i gnment marks on the pi ni on and
press fl ange onto the pi ni on.
(3) I nstal l fl ange nut and ti ghten to 244 Nm (180
ft. l bs.).
Fig. 29 Output Flange Nut
Fig. 30 Mark Flange and Shaft
(4) I nstal l rear cover. Use care not to cut rear
cover O-Ri ng when i nstal l i ng rear cover i nto P.T.U.
housi ng.
(5) I nstal l rear cover retai ni ng bol ts and ti ghten to
28 Nm (250 i n. l bs.).
(6) I nstal l propel l er shaft.
INPUT SHAFT COVER SEAL
The power transfer uni t i nput shaft cover seal i s
the l arger of the two seal s l ocated on the i nsi de of
the end cover. The di fferenti al beari ng cup must be
removed to servi ce thi s seal .
vehi cl e to perform thi s operati on.
REMOVAL
(2) Gentl y tap on end cover ears to separate cover
(3) Use speci al tool No. 6514 and remove the di f-
ferenti al beari ng race l ocated i n the end cover (Fi g.
35). The race must be removed to gai n access to the
seal .
(4) Use speci al tool No. 7794-A to remove seal (Fi g.
36).
INSTALLATION
(2) Use speci al tool No. MD998803 and i nstal l seal
(Fi g. 37). When i nstal l i ng seal the spri ng si de of the
seal must face toward the speci al tool .
(3) Rei nstal l the ori gi nal beari ng race and shi m
usi ng speci al tool No. 6522 (Fi g. 38) and (Fi g. 39).
CAUTION: The original shim must be installed
behind the bearing cup to maintain proper bearing
preload.
(4) Appl y Mopar Gasket Maker, Locti te Gasket
El i mi nator No. 518 or equi val ent to seal i ng surfaces
of end cover.
(5) Pl ace end cover onto P.T.U. case and i nstal l
bol ts. Ti ghten bol ts to 28 Nm (250 i n. l bs.) i n the
sequence shown i n (Fi g. 40). Reti ghten fi rst bol t after
al l others are ti ght.
Fig. 35 Bearing Race Removal
(6) Rei nstal l P.T.U. assembl y i nto vehi cl e.
HALF SHAFT INNER SEAL
The power transfer uni t hal f shaft i nner seal i s the
smal l er of the two seal s l ocated on the i nsi de of the
end cover.
REMOVAL
(1) Remove power transfer uni t from the vehi cl e.
(2) Remove end cover bol ts (Fi g. 41).
(3) Tap on end cover ears to separate cover from
case (Fi g. 42).
(4) Dri ve seal out wi th a hammer and smal l chi sel
(Fi g. 43).
Fig. 38 Bearing Shim and Race
Fig. 39 Installing Bearing Race
INSTALLATION
(2) I nstal l seal wi th a 1 1/16 i nch socket (Fi g. 44).
The seal must be i nstal l ed wi th the spri ng si de of the
seal faci ng end cover bal l beari ng. The seal wi l l bot-
tom agai nst a machi ned shoul der i n the cover.
(3) Cl ean seal i ng surfaces of the end cover and
P.T.U. case. Appl y a bead of Mopar Gasket Maker,
Locti te Gasket El i mi nator No. 518 or equi val ent.
Fig. 41 End Cover Bolts
al l other bol ts are ti ght.
(5) Rei nstal l P.T.U. assembl y.
INPUT SHAFT END SEAL
The i nput shaft end seal i s l ocated on the end of
the i nput shaft.
REMOVAL
(1) Remove power transfer uni t from the vehi cl e.
(2) Remove end cover bol ts (Fi g. 46).
(3) Tap on end cover ears to separate end cover
(4) Pry out seal wi th a pry bar (Fi g. 48).
INSTALLATION
(2) Remove i nput shaft from housi ng and stand on
soft bl ock of wood. I nstal l i nput shaft end seal wi th
seal i nstal l er 5065 and handl e C-4171.
(3) Lubri cate seal l i p after i nstal l i ng seal i nto
i nput shaft.
(4) Cl ean seal i ng surfaces of the end cover and
P.T.U. case. Appl y a bead of Mopar Gasket Maker,
Locti te Gasket El i mi nator No. 518 or equi val ent.
al l others are ti ght.
(6) Rei nstal l P.T.U. assembl y.
OUTER HALF SHAFT SEAL
The outer hal f shaft seal i s l ocated on the outsi de
of the end cover. The P.T.U. does not have to be
removed to repl ace thi s seal .
Fig. 46 End Cover Bolts
Fig. 47 Side Cover Removal
REMOVAL
(1) Li ft vehi cl e on hoi st.
(2) Remove ri ght front hal f shaft from vehi cl e.
(3) Remove seal wi th a chi sel and hammer (Fi g.
50).
INSTALLATION
(2) I nstal l new seal wi th seal i nstal l er MD998334
(Fi g. 51).
(3) Rei nstal l ri ght front hal f shaft.
END COVER BALL BEARING
The end cover bal l beari ng can be removed and
i nstal l ed wi thout removi ng the Power Transfer Uni t
from the vehi cl e. When repl aci ng the beari ng the out-
put seal must be removed to gai n access to the bear-
i ng.
REMOVAL
(2) Remove ri ght front hal f shaft from vehi cl e.
(3) Remove output seal wi th a hammer and chi sel
(Fi g. 52).
(4) Remove beari ng retai ni ng snap ri ng (Fi g. 53).
(5) Use beari ng pul l er MD998346 to remove bear-
i ng (Fi g. 54).
INSTALLATION
(1) Use beari ng dri ver L-4530 and handl e C-4171-2
to i nstal l beari ng (Fi g. 55).
(2) I nstal l beari ng retai ni ng snap ri ng.
CAUTION: When installing bearing retaining snap
ring, be sure to index the snap ring so that the
snap ring does not cover bearing oil passage.
(3) I nstal l new outer hal f shaft seal usi ng
MD998334 seal i nstal l er (Fi g. 56). Do not reuse the
old seal.
(4) Rei nstal l ri ght front hal f shaft.
Fig. 52 Output Seal Removal
Fig. 53 Bearing Snap Ring
Fig. 54 Bearing Removal
Fig. 55 Bearing Installation
Fig. 56 Installing New Seal
ADJ USTMENTS
OUTPUT FLANGE SHIM SELECTION
Thi s procedure i s used when the output fl ange i s
repl aced. Repl acement of the output fl ange requi res
i nstal l ati on of the correct si ze shi m to mai ntai n bear-
i ng prel oad. The shim must protrude from the
new output flange the same distance that the
original shim protruded from the original
flange.
(1) Stand the ori gi nal output fl ange on end wi th
shi m si de poi nti ng up.
(2) Pl ace ori gi nal shi m i nto groove i n top of fl ange.
(3) Pl ace a strai ght edge across the shi m.
(4) Usi ng feel er gauge, measure the di stance
between the strai ght edge and the top of the fl ange
(Fi g. 57). Record thi s measurement.
(5) Repeat steps Step 1 through Step 4 usi ng the
new flange and the original shim. Record thi s
measurement.
(6) I f measurements are not equal , use a new shi m
that protrudes from new output fl ange. Make sure i t
protrudes the same amount.
(7) For Exampl e: The ori gi nal shi m protrudes
0.075 i nch from the ori gi nal output fl ange. Pl ace the
original shim i nto the new output fl ange. The pro-
trusi on of the shi m i n the new fl ange i s 0.085 i nch.
Thi s i ndi cates that a 0.010 i nch thi nner shi m i s
requi red to mai ntai n the ori gi nal protrusi on.
(8) I nstal l output fl ange and torque fl ange nut to
244 Nm (180 ft. l bs.).
(9) Check the turni ng torque of the pi ni on before
i nstal l i ng the rear cover i nto the P.T.U. The turni ng
torque shoul d be between 2.0 Nm and 2.5 Nm (17
i n. l bs. and 22 i n. l bs.).
SPECIFICATIONS
TORQUE
DESCRIPTION TORQUE
End Cover . . . . . . . . . . . . . . . . .28 Nm (250 i n. l bs.)
Fi l l Pl ug . . . . . . . . . . . . . . . . . . .27 Nm (240 i n. l bs.)
Fl ange Nut . . . . . . . . . . . . . . . .162 Nm (120 ft. l bs.)
I nspecti on Pl ug . . . . . . . . . . . . .20 Nm (180 i n. l bs.)
Rear Cover . . . . . . . . . . . . . . . . .28 Nm (250 i n. l bs.)
Ri ng Gear . . . . . . . . . . . . . . . . . . .94 Nm (70 ft. l bs.)
Fig. 57 Output Flange Shim Measurement
SPECIAL TOOLS
SDP POWER TRANSFER UNIT
5049-a Seal Puller
5065 Bearing Installer
6514 Bearing Remover
6522 Bearing Remover
7794-a Bearing Remover
C-4171 Handle
C-4171-2 Handle Extension
C-4657 Seal Installer
A598 MANUAL TRANSAXLE
CONTENTS
page page
GENERAL INFORMATION
A-598 MANUAL TRANSAXLE . . . . . . . . . . . . . . . 2
A-558 MANUAL TRANSAXLERHD
VEHICLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
GEAR RATIOS . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
GEAR RATIOSRHD VEHICLES . . . . . . . . . . . . 3
GEARSHIFT PATTERN. . . . . . . . . . . . . . . . . . . . . 3
GEARSHIFT PATTERNRHD VEHICLES . . . . . . 3
SELECTION OF LUBRICANT . . . . . . . . . . . . . . . . 2
SELECTION OF LUBRICANTRHD VEHICLES . 2
SPECIAL ADDITIVES . . . . . . . . . . . . . . . . . . . . . 2
SPECIAL ADDITIVESRHD VEHICLES . . . . . . . 3
TRANSAXLE IDENTIFICATION INFORMATION . . 2
TRANSAXLE IDENTIFICATION
INFORMATIONRHD VEHICLES . . . . . . . . . . 2
AXLE SEALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
GEARSHIFT LEVERS . . . . . . . . . . . . . . . . . . . . . . 3
CLUTCH PROBLEMS . . . . . . . . . . . . . . . . . . . . . 4
COMMON PROBLEM CAUSES . . . . . . . . . . . . . . 3
HARD SHIFTING . . . . . . . . . . . . . . . . . . . . . . . . . 4
LOW LUBRICANT LEVEL . . . . . . . . . . . . . . . . . . 4
NOISY OPERATION . . . . . . . . . . . . . . . . . . . . . . . 4
SLIPS OUT OF GEAR . . . . . . . . . . . . . . . . . . . . . 4
SERVICE PROCEDURES
FLUID DRAIN AND FILL . . . . . . . . . . . . . . . . . . . 4
FLUID DRAIN AND FILLRHD VEHICLES . . . . 4
A-558 TRANSAXLE ASSEMBLYRHD
VEHICLES . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
AXLE SEALS . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
BACK-UP LAMP SWITCH . . . . . . . . . . . . . . . . . . 9
2.5L VM DIESEL . . . . . . . . . . . . . . . . . . . . . . 10
CROSSOVER LEVER . . . . . . . . . . . . . . . . . . . . . 11
GEARSHIFT BOOT . . . . . . . . . . . . . . . . . . . . . . . 5
GEARSHIFT BOOT . . . . . . . . . . . . . . . . . . . . . . . 5
GEARSHIFT CABLES . . . . . . . . . . . . . . . . . . . . . . 5
GEARSHIFT CABLESRHD VEHICLES . . . . . . . 7
GEARSHIFT KNOB . . . . . . . . . . . . . . . . . . . . . . . 5
GEARSHIFT MECHANISM REPLACEMENT . . . . . 7
GEARSHIFT MECHANISM REPLACEMENT
RHD VEHICLES . . . . . . . . . . . . . . . . . . . . . . . . 8
INPUT SHAFT FRONT BEARING RETAINER . . . 15
INPUT SHAFT SEAL . . . . . . . . . . . . . . . . . . . . . 16
SELECTOR LEVER . . . . . . . . . . . . . . . . . . . . . . 11
SHIFT SHAFT SEALS . . . . . . . . . . . . . . . . . . . . 12
TRANSAXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
VEHICLE SPEED SENSOR DRIVE GEAR . . . . . . 9
DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . 39
INPUT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . 32
INTERMEDIATE SHAFT . . . . . . . . . . . . . . . . . . . 33
SHIFT COVER . . . . . . . . . . . . . . . . . . . . . . . . . . 45
SYNCHRONIZER . . . . . . . . . . . . . . . . . . . . . . . . 43
TRANSAXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
TRANSAXLE CASE . . . . . . . . . . . . . . . . . . . . . . 48
SYNCHRONIZER . . . . . . . . . . . . . . . . . . . . . . . . 52
TRANSAXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
ADJUSTMENTS
BEARING ADJ USTMENT PROCEDURE . . . . . . . 56
GEARSHIFT CROSSOVER CABLE . . . . . . . . . . . 52
GEARSHIFT CROSSOVER CABLE . . . . . . . . . . . 55
INTERMEDIATE SHAFT BEARING PRELOAD . . 57
SPECIFICATIONS
VEHICLES . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
A-598 (T-750) MANUAL TRANSAXLE . . . . . . . 59
SPECIAL TOOLS
VEHICLES . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
A-598 (T-750) MANUAL TRANSAXLE . . . . . . . 60
NS/GS A598 MANUAL TRANSAXLE 21 - 1
GENERAL INFORMATION
A-598 MANUAL TRANSAXLE
Safety goggles should be worn at all times
when working on these transaxles. The A-598
manual transaxl e uses SAE 5W-30 engi ne oi l , meet-
i ng SG and/or SG-CD qual i fi cati ons, as the factory
fi l l l ubri cant. SAE G5 10W-40 engi ne oi l i s a sui tabl e
servi ce fi l l al ternati ve.
Thi s transaxl e combi nes gear reducti on, rati o sel ec-
ti on, and di fferenti al functi ons i n one uni t. I t i s
housed i n a di e-cast al umi num case.
A-558 MANUAL TRANSAXLE RHD VEHICLES
Safety goggles should be worn at all times
when working on these transaxles. The A-558
manual transaxl e uses SAE 5W-30 engi ne oi l , meet-
i ng SG and/or SG-CD qual i fi cati ons, as the factory
fi l l l ubri cant. SAE G5 10W-40 engi ne oi l i s a sui tabl e
servi ce fi l l al ternati ve.
Thi s transaxl e combi nes gear reducti on, rati o sel ec-
ti on, and di fferenti al functi ons i n one uni t. I t i s
housed i n a di e-cast al umi num case.
TRANSAXLE IDENTIFICATION INFORMATION
The A-598 transaxl e model , assembl y number,
bui l d date, and fi nal -dri ve rati o are stamped on a tag
that i s attached to the top of the transaxl e (Fi g. 1).
The l ast ei ght di gi ts of the Vehi cl e I denti fi cati on
Number (V.I .N.) are stamped on a rai sed boss on top
of the cl utch housi ng area.
TRANSAXLE IDENTIFICATION INFORMATION RHD
VEHICLES
The A-558 transaxl e model , assembl y number,
bui l d date, and fi nal -dri ve rati o are stamped on a tag
that i s attached to the top of the transaxl e (Fi g. 2).
NOTE: Certain transaxle assemblies utilize high-
strength steel in various gears. It is imperative that
the correct transaxle assembly number is utilized
when ordering service parts. Do not remove this
tag, so the information is available for future ser-
vice.
The l ast ei ght di gi ts of the Vehi cl e I denti fi cati on
Number (V.I .N.) are stamped on a rai sed boss on top
of the cl utch housi ng area.
The A-598 manual transaxl e uses SAE 5W-30
engi ne oi l , meeti ng SG and/or SG-CD qual i fi cati ons,
as the factory fi l l l ubri cant. G5 SAE 10W-40 engi ne
oi l i s a sui tabl e servi ce fi l l al ternati ve. Hypoid gear
lube, manual transmission fluid, and/or auto-
matic transmission fluid should not be used in
this transaxle. Hard shi fti ng effort, beari ng, gear,
and/or synchroni zer fai l ure may occur i f i ncorrect
fl ui d i s used.
SELECTION OF LUBRICANT RHD VEHICLES
The A-558 manual transaxl e uses SAE 5W-30
engi ne oi l , meeti ng SG and/or SG-CD qual i fi cati ons,
as the factory fi l l l ubri cant. G5 SAE 10W-40 engi ne
oi l i s a sui tabl e servi ce fi l l al ternati ve. Hypoid gear
lube, manual transmission fluid, and/or auto-
matic transmission fluid should not be used in
this transaxle. Hard shi fti ng effort, beari ng, gear,
and/or synchroni zer fai l ure may occur i f i ncorrect
fl ui d i s used.
SPECIAL ADDITIVES
The addi ti on of any fl ui ds to the transaxl e, other
than the fl ui d l i sted above, i s not recommended. An
excepti on to thi s pol i cy i s the use of speci al dyes to
ai d i n detecti ng fl ui d l eaks. The use of transmi ssi on
Fig. 1 Transaxle Identification
Fig. 2 Transaxle Identification
21 - 2 A598 MANUAL TRANSAXLE NS/GS
seal ers shoul d be avoi ded, si nce they may adversel y
affect seal s.
SPECIAL ADDITIVES RHD VEHICLES
The addi ti on of any fl ui ds to the transaxl e, other
than the fl ui d l i sted above, i s not recommended. An
excepti on to thi s pol i cy i s the use of speci al dyes to
ai d i n detecti ng fl ui d l eaks. The use of transmi ssi on
seal ers shoul d be avoi ded, si nce they may adversel y
affect seal s.
GEAR RATIOS
Gear rati os for the 2.4L gasol i ne engi ne and 2.5L
Turbo Di esel MTX are as fol l ows:
1st3.36
2nd1.90
3rd1.28
4th0.92
5th0.71
Reverse3.17
Fi nal dri ve rati o of 3.88 was sel ected for maxi mum
performance. Al l forward gears are synchroni zed.
Gear rati os for the 2.0L GAS MTX are as fol l ows:
1st3.69
2nd2.24
3rd1.45
4th1.03
5th0.81
Reverse3.17
GEAR RATIOS RHD VEHICLES
Gear rati os for the 2.0L GAS MTX are as fol l ows:
1st3.69
2nd2.24
3rd1.45
4th0.1.03
5th0.81
Reverse3.17
GEARSHIFT PATTERN
The A-598 transaxl e shi ft pattern i s a Hpattern
(Fi g. 3). Overdri ve fi fth and reverse gears are i nl i ne
and to the ri ght of the fi rst through fourth gear posi -
ti ons.
GEARSHIFT PATTERN RHD VEHICLES
The A-558 transaxl e shi ft pattern i s a Hpattern
(Fi g. 4). Overdri ve fi fth and reverse gears are i nl i ne
and to the ri ght of the fi rst through fourth gear posi -
ti ons.
GEARSHIFT LEVERS
The gear shi ft l evers at the transaxl e are servi ce-
abl e i n the vehi cl e. The shi ft l evers are di fferent from
each other and do not i nterchange. The sel ect l ever i s
not i nterchangeabl e wi th model years earl i er than 96
(l ength i s di fferent).
AXLE SEALS
The axl e shaft seal s are i denti cal for both si des of
the di fferenti al and wi l l i nterchange.
COMMON PROBLEM CAUSES
The majori ty of transaxl e mal functi ons are a resul t
of:
I nsuffi ci ent l ubri cati on
I ncorrect l ubri cant
Mi sassembl ed or damaged i nternal components
Fig. 3 A-598 Shift Pattern
Fig. 4 A-558 Shift Pattern
I mproper operati on
HARD SHIFTING
Hard shi fti ng may be caused by a mi sadjusted
crossover cabl e. I f hard shi fti ng i s accompani ed by
gear cl ash, synchroni zer cl utch and stop ri ngs or gear
teeth may be worn or damaged.
Mi sassembl ed synchroni zer components al so cause
shi fti ng probl ems. I ncorrectl y i nstal l ed synchroni zer
sl eeves, struts, or spri ngs can cause shi ft probl ems.
NOISY OPERATION
Transaxl e noi se i s most often a resul t of worn or
damaged components. Chi pped, broken gear or syn-
chroni zer teeth, and bri nnel l ed, spal l ed beari ngs al l
cause noi se.
Abnormal wear and damage to the i nternal compo-
nents i s frequentl y the end resul t of i nsuffi ci ent
l ubri cant.
SLIPS OUT OF GEAR
Transaxl e di sengagement may be caused by mi s-
al i gned or damaged shi ft components, or worn teeth
on the dri ve gears or synchroni zer components. I ncor-
rect assembl y al so causes gear di sengagement.
LOW LUBRICANT LEVEL
I nsuffi ci ent transaxl e l ubri cant i s usual l y the
resul t of l eaks, or i naccurate fl ui d l evel check or refi l l
method. Leakage i s evi dent by the presence of oi l
around the l eak poi nt. I f l eakage i s not evi dent, the
condi ti on i s probabl y the resul t of an underfi l l .
I f ai rpowered l ubri cati on equi pment i s used to fi l l
a transaxl e, be sure the equi pment i s properl y cal i -
brated. Equi pment out of cal i brati on can l ead to an
underfi l l condi ti on.
The transaxl e fi l l pl ug i s l ocated on the l ower l eft
si de of the transaxl e end cover. Wi th the vehi cl e at a
l evel posi ti on, remove the fi l l pl ug and check the
l evel of the l ubri cant. The l ubri cant l evel shoul d be
wi thi n 3.175mm (1/8 i nch) from the bottom of the fi l l
hol e. I f the l ubri cant l evel i s l ow, fi l l the transaxl e to
the bottom of the fi l l hol e wi th SAE 5W-30 engi ne oi l ,
meeti ng SG and/or SG-CD qual i fi cati ons, as the fac-
tory fi l l l ubri cant. SAE GL5 10W-40 engi ne oi l i s a
sui tabl e servi ce fi l l al ternati ve.
CLUTCH PROBLEMS
Worn, damaged, or mi sal i gned cl utch components
can cause di ffi cul t shi fti ng, gear cl ash, and noi se.
A worn or damaged cl utch di sc, pressure pl ate, or
rel ease beari ng can cause hard shi fti ng and gear
cl ash.
SERVICE PROCEDURES
FLUID DRAIN AND FILL
TRANSAXLE FLUID DRAIN
(2) I nstal l a drai n pan underneath the transaxl e
drai n pl ug.
(3) Remove the transaxl e drai n pl ug. The drai n
pl ug i s l ocated on the bottom of the transaxl e hous-
i ng.
(4) Let fl ui d drai n out ti l l there i s just an occa-
si onal dri p.
(5) Rei nstal l drai n pl ug. Ti ghten drai n pl ug to 28
Nm (250 i n. l bs.)
TRANSAXLE FLUID FILL
NOTE: All A-598 transaxles are equipped with a fill
plug. The fill plug is located on the end cover side
of the transaxle.
(1) Remove transaxl e fi l l pl ug
The fl ui d l evel shoul d be wi thi n 3.175mm (1/8
i nch) from the bottom of the transaxl e fi l l hol e (vehi -
cl e must be l evel when checki ng).
(2) Fi l l transaxl e to proper l evel wi th SAE 5W-30
engi ne oi l , meeti ng SG and/or SG-CD qual i fi cati ons.
G5 SAE 10W-40 engi ne oi l i s a sui tabl e servi ce fi l l
al ternati ve. Dry fi l l l ubri cant capaci ty i s approxi -
matel y 1.9-2.2 l i ters (4.0-4.6 pi nts)..
(3) Wi pe the outsi de of the transaxl e i f any l ubri -
cant spi l l s.
(4) Rei nstal l transaxl e fi l l pl ug.
FLUID DRAIN AND FILL RHD VEHICLES
TRANSAXLE FLUID DRAIN
(2) I nstal l a drai n pan underneath the transaxl e
drai n pl ug.
(3) Remove the transaxl e drai n pl ug. The drai n
pl ug i s l ocated on the bottom of the transaxl e hous-
i ng (Fi g. 5).
(4) Let fl ui d drai n out ti l l there i s just an occa-
si onal dri p.
(5) Rei nstal l drai n pl ug. Ti ghten drai n pl ug to 28
Nm (250 i n. l bs.)
TRANSAXLE FLUID FILL
NOTE: All A-558 transaxles are equipped with a fill
plug. The fill plug is located on the end cover side
of the transaxle.
(1) Remove transaxl e fi l l pl ug
The fl ui d l evel shoul d be wi thi n 3.175mm (1/8
i nch) from the bottom of the transaxl e fi l l hol e (vehi -
cl e must be l evel when checki ng).
(2) Fi l l transaxl e to proper l evel wi th SAE 5W-30
engi ne oi l , meeti ng SG and/or SG-CD qual i fi cati ons.
G5 SAE 10W-40 engi ne oi l i s a sui tabl e servi ce fi l l
al ternati ve. Dry fi l l l ubri cant capaci ty i s approxi -
matel y 1.9-2.2 l i ters (4.0-4.6 pi nts).
(3) Wi pe the outsi de of the transaxl e i f any l ubri -
cant spi l l s.
(4) Rei nstal l transaxl e fi l l pl ug.
GEARSHIFT KNOB
REMOVAL
(1) Pul l shi fter boot down and away from shi fter
rol l pi n.
(2) Pry l egs of shi ft knob away from shi ft l ever rol l
pi n usi ng a fl at bl ade pry tool (Fi g. 6).
(3) Remove knob from shi fter handl e.
INSTALLATION
(1) For i nstal l ati on, reverse removal procedure,
omi tti ng step (2).
GEARSHIFT BOOT
REMOVAL
(1) Remove shi fter knob. Refer to gearshi ft knob
removal .
(2) Pul l up on boot unti l retenti on cl i ps di sengage
from the consol e and remove (Fi g. 7).
INSTALLATION
taki ng care to ful l y engage the retenti on cl i ps.
GEARSHIFT BOOT
REMOVAL
(1) Remove shi fter knob. Refer to gearshi ft knob
removal .
(2) Pul l up on boot unti l retenti on cl i ps di sengage
from the consol e and remove (Fi g. 8).
INSTALLATION
taki ng care to ful l y engage the retenti on cl i ps.
GEARSHIFT CABLES
REMOVAL
(3) Di sconnect gearshi ft cabl e ends from transaxl e
shi ft l evers (Fi g. 9) (Fi g. 10).
CAUTION: Pry up with equal force on both sides of
shifter cable isolator bushings to avoid damaging
cable isolator bushings.
Fig. 5 Transaxle Drain Plug
Fig. 6 Shifter Knob
Fig. 7 Shifter Boot
(4) Remove cabl e to bracket retai ni ng cl i ps at tran-
saxl e (Fi g. 11).
CAUTION: It is recommended that new cable retain-
ing clips be used for reinstallation.
(5) Pul l cabl es up out of engi ne mount bracket.
(6) Remove gearshi ft knob and boot. Refer to Knob
and Boot Removal i n thi s secti on.
(7) Remove consol e screws (Fi g. 12).
(8) Remove cabl e retai ni ng cl i ps at shi fter (Fi g. 13)
(Fi g. 14).
ing clips be used for reinstallation. Clips must be
installed to span the slotted holes.
(9) Di sconnect shi ft cabl es from shi fter. Pry wi th
equal force on both si des of shi fter cabl e i sol ator
bushi ngs to avoi d damagi ng bushi ngs.
(10) Li ft vehi cl e on hoi st. Cut gearshi ft cabl e ti e
strap at fl oor pan wi th di agonal cutters.
(11) Remove shi ft cabl es from vehi cl e by graspi ng
cabl es and grommets one at a ti me and tuggi ng down
through fl oor pan hol es (Fi g. 15).
Fig. 8 Gearshift Boot
Fig. 9 Crossover Lever Shift Cable
Fig. 10 Selector Lever Shift Cable
Fig. 11 Cable Retaining Clip
Fig. 12 Gearshift Console
INSTALLATION
(1) To i nstal l , reverse removal procedure. After
cabl es have been repl aced, cabl e adjustment shoul d
be checked. Refer to cabl e adjustment procedure i n
thi s secti on.
NOTE: High temperature tie straps must be used
when replacing cable(s). Locate the new tie strap at
the white band on the crossover cable and cinch
cables tightly together.
CAUTION: Only the crossover cable is adjustable.
The selector cable does not have any adjustment
capabilities.
GEARSHIFT CABLES RHD VEHICLES
REMOVAL
(3) Di sconnect gearshi ft cabl e ends from transaxl e
shi ft l evers (Fi g. 16) (Fi g. 17).
CAUTION: Pry up with equal force on both sides of
shifter cable isolator bushings to avoid damaging
cable isolator bushings.
(4) Remove cabl e to bracket retai ni ng cl i ps at tran-
saxl e (Fi g. 18).
ing clips be used for reinstallation.
(5) Pul l cabl es up out of engi ne mount bracket.
(6) Remove gearshi ft knob and boot. Refer to Knob
and Boot Removal i n thi s secti on.
(7) Remove consol e screws (Fi g. 19).
(8) Remove cabl e retai ni ng cl i ps at shi fter (Fi g. 20)
(Fi g. 21).
ing clips be used for reinstallation. Clips must be
installed to span the slotted holes.
(9) Di sconnect shi ft cabl es from shi fter. Pry wi th
equal force on both si des of shi fter cabl e i sol ator
bushi ngs to avoi d damagi ng bushi ngs.
(10) Li ft vehi cl e on hoi st. Cut gearshi ft cabl e ti e
strap at fl oor pan wi th di agonal cutters.
(11) Remove shi ft cabl es from vehi cl e by graspi ng
cabl es and grommets one at a ti me and tuggi ng down
through fl oor pan hol es (Fi g. 22).
INSTALLATION
(1) To i nstal l , reverse removal procedure. After
cabl es have been repl aced, cabl e adjustment shoul d
be checked. Refer to cabl e adjustment procedure i n
thi s secti on.
NOTE: High temperature tie straps must be used
when replacing cable(s). Locate the new tie strap at
the white band on the crossover cable and cinch
cables tightly together.
CAUTION: Only the crossover cable is adjustable.
The selector cable does not have any adjustment
capabilities.
GEARSHIFT MECHANISM REPLACEMENT
REMOVAL
(1) Remove shi fter knob and boot. refer to Shi fter
Knob And Boot Removal procedure i n thi s secti on.
(2) Remove consol e assembl y. Refer to Consol e
Removal procedure i n thi s secti on.
Fig. 13 Selector Cable Clip
Fig. 14 Crossover Cable Clip
(3) Remove gearshi ft cabl es. Refer to Gearshi ft
Cabl e Removal i n thi s secti on.
(4) Remove retai ni ng nuts at the base of the gear-
shi ft mechani sm. Remove shi fter.
INSTALLATION
GEARSHIFT MECHANISM REPLACEMENT RHD
VEHICLES
REMOVAL
(1) Remove shi fter knob and boot. Refer to Shi fter
Knob And Boot Removal procedure i n thi s secti on.
(2) Remove consol e assembl y. Refer to Consol e
Removal procedure i n Group 23 i n thi s manual .
Fig. 15 Gearshift Cables
Fig. 16 Crossover Lever Shift Cable Fig. 17 Selector Lever Shift Cable
(3) Remove gearshi ft cabl es. Refer to Gearshi ft
Cabl e Removal i n thi s secti on.
(4) Remove retai ni ng nuts at the base of the gear-
shi ft mechani sm. Remove shi fter.
INSTALLATION
VEHICLE SPEED SENSOR DRIVE GEAR
REMOVAL
(2) Remove wi ri ng connector from speed sensor.
CAUTION: Clean area around speed sensor before
removing. This will prevent the possibility of dirt
from entering the transaxle during speed sensor
removal.
(3) Remove speed sensor retai ni ng bol t.
(4) Remove speed sensor from transaxl e extensi on
CAUTION: Carefully remove vehicle speed sensor
so that sensor drive gear does not fall into tran-
saxle. Should sensor drive gear fall into the tran-
saxle during sensor removal, drive gear must be
reattached to sensor.
(5) Remove speed sensor dri ve gear from speed
sensor.
INSTALLATION
(2) Confi rm vehi cl e speedometer i s functi oni ng
properl y fol l owi ng i nstal l ati on.
BACK-UP LAMP SWITCH
The back-up l amp swi tch i s l ocated on the gear-
shi ft housi ng on top of the transaxl e case.
REMOVAL
(1) From top si de of vehi cl e, remove wi ri ng connec-
tor from swi tch (Fi g. 24).
(2) Unscrew swi tch from transaxl e.
Fig. 18 Cable Retaining Clip
Fig. 20 Selector Cable Clip
Fig. 21 Crossover Cable Clip
INSTALLATION
(1) To i nstal l , reverse removal procedure. Tefl on
tape or equi val ent must be used on swi tch threads.
CAUTION: Do not overtighten switch.
(2) Confi rm back-up l amps are functi oni ng prop-
erl y fol l owi ng i nstal l ati on.
CRANKSHAFT POSITION SENSOR 2. 5L VM
DIESEL
The crankshaft posi ti on sensor i s l ocated on the
transaxl e bel l housi ng. The sensor measures the posi -
ti on of the crankshaft and rel ays that i nformati on to
the Powertrai n Control Modul e.
Fig. 22 Gearshift Cables
Fig. 23 Vehicle Speed Sensor Fig. 24 Back-Up Lamp Switch Location
REMOVAL
(1) Remove el ectri cal connector at crankshaft posi -
ti on sensor (Fi g. 25).
(2) Remove screw retai ni ng the crankshaft posi ti on
sensor to the bel l housi ng.
(3) Remove the crankshaft posi ti on sensor.
INSTALLATION
CROSSOVER LEVER
REMOVAL
(1) Remove crossover cabl e. Refer to Gearshi ft
Cabl e removal .
(2) Usi ng a pi n punch, remove the crossover rol l
pi n from l ever.
(3) Pul l up and remove the crossover l ever from
the transaxl e crossover shaft.
INSTALLATION
Repl ace the rol l pi n that was removed wi th a new
one.
SELECTOR LEVER
REMOVAL
(1) Remove the sel ector cabl e. Refer to Gearshi ft
Cabl e removal .
(2) Usi ng a pi n punch, remove the rol l pi n from
the l ever.
(3) Remove the sel ector l ever from the transaxl e
sel ector shaft
INSTALLATION
Repl ace the rol l pi n wi th a new one.
AXLE SEALS
The axl e shaft seal s are i denti cal for both si des of
the di fferenti al and wi l l i nterchange.
EXTENSION HOUSING AXLE SEAL
REMOVAL
(1) Remove axl e shaft. Refer to Group 2, Suspen-
si on and Dri veshafts for servi ce procedures.
(2) I nsert a fl atbl ade pry tool i nto the axl e seal
bore (Fi g. 26).
(3) Usi ng the pry tool , careful l y pop out the seal
taki ng care not to ni ck the seal bore.
INSTALLATION
(1) Cl ean axl e shaft seal bore of any excess seal -
ant.
(2) Al i gn axl e shaft seal wi th axl e shaft seal bore.
(3) Posi ti on axl e seal at extensi on housi ng.
(4) Usi ng Tool L-4520 and Tool C-4171, tap seal
i nto posi ti on (Fi g. 27).
Fig. 26 Extension Housing Axle Seal
Fig. 27 Install Seal
DIFFERENTIAL BEARING RETAINER AXLE
SEAL
REMOVAL
(1) Remove axl e shaft. Refer to Group 2, Suspen-
si on and Dri veshafts for servi ce procedures.
(2) I nsert a fl atbl ade pry tool i nto the axl e seal
bore.
(3) Usi ng the pry tool , careful l y pop out the seal
taki ng care not to ni ck the seal bore.
INSTALLATION
(1) Cl ean axl e shaft seal bore of any excess seal -
ant.
(2) Al i gn axl e shaft seal wi th axl e shaft seal bore.
(3) Posi ti on axl e seal at extensi on housi ng.
(4) Usi ng Tool L-4520 and Tool C-4171, tap seal
i nto posi ti on.
SHIFT SHAFT SEALS
I t i s not necessary to remove the shi ft shaft cover
from the transaxl e to servi ce the shi ft shaft seal s.
REMOVAL
(1) Remove the shi ft l ever from the seal that i s to
be servi ced. Refer to shi ft l ever removal for servi ce
procedure.
(2) Usi ng a pi ck tool , pry up on the shi ft shaft seal
and remove seal from bore.
INSTALLATION
(1) Posi ti on new shi ft shaft seal i n bore.
(2) I nstal l shi ft shaft seal i nto bore usi ng an
appropri ate si ze deepwel l socket.
TRANSAXLE
The fol l owi ng i tems can be servi ced wi thout remov-
i ng the transaxl e from the vehi cl e:
Gearshi ft housi ng
5th speed synchroni zer
5th speed gear
Rol l er detents and spri ngs
Speedometer pi ni on
Vehi cl e speed sensor
Beari ng retai ner pl ate.
Al l external covers
Shi ft shaft seal s
Axl e shaft seal s
To servi ce any other component of the A-598 tran-
saxl e you must remove i t from the vehi cl e.
REMOVAL
(2) Remove ai r i ntake hose. Di sconnect ai r mass
meter connector.
(3) Remove i ntercool er hose.
(4) Remove connectors for back-up l amp (Fi g. 28)
and crank posi ti on sensor (Fi g. 29).
(5) Remove crank posi ti on sensor (2.5L VM Di esel
onl y).
(6) Remove wi ri ng harness bracket at transaxl e
(Fi g. 30).
(7) Remove crossover and shi ft sel ector cabl es (Fi g.
31).
(8) Remove the two top bol ts at the rear engi ne
mount bracket.
(9) Remove bol ts securi ng the cool ant reservoi r to
the top of the engi ne. Move the cool ant reservoi r out
of the way.
(10) I nstal l an engi ne support chai n to the cyl i nder
head assembl y (Fi g. 32).
Fig. 28 Back-up Lamp Connector
(11) Remove three upper bel l housi ng bol ts (Fi g.
33).
(12) I nstal l engi ne bri dge fi xture to chai n and sup-
port engi ne (Fi g. 34).
(13) Hoi st the vehi cl e.
(14) Remove front wheel s.
(15) Remove axl e shaft hub nuts.
(16) Remove steeri ng knuckl e steeri ng stop studs.
(17) Remove l ower control arm pi nch bol ts (Fi g.
35).
(18) Usi ng a pry bar, unseat l ower control arm
from steeri ng knuckl e (Fi g. 36).
(19) Remove drai n pl ug and drai n transaxl e fl ui d
(Fi g. 37).
(20) Remove ri ght and l eft axl e shaft assembl i es
(21) Remove vehi cl e speed sensor wi ri ng connector
(Fi g. 38).
(22) Remove cl utch cabl e retai ni ng cl i p (Fi g. 39).
Remove cl utch cabl e from transaxl e housi ng.
(23) Remove adapter pl ate and front engi ne mount
bol ts (Fi g. 40) (Fi g. 41).
(24) Remove two remai ni ng rear engi ne mount
bol ts.
CAUTION: Always use a safety chain when remov-
ing or installing transaxle assembly.
Fig. 30 Wiring Harness Bracket
Fig. 31 Shift Cables
Fig. 32 Engine Support Chain
Fig. 33 Upper Bellhousing Bolts
Fig. 34 Engine Bridge Fixture
(25) I nstal l transmi ssi on jack under transaxl e
assembl y.
(26) Remove l eft fender spl ash shi el d.
(27) Remove (4) l eft mount bol ts (Fi g. 42).
(28) Remove l ower bel l housi ng bol ts.
(29) Lower transaxl e and remove.
INSTALLATION
NOTE: Lower control arm pinch bolts must be
installed with the bolt heads to the rear of the ball
joints.
Fig. 35 Lower Control Arm Pinch Bolt
Fig. 36 Unseat Control Arm
Fig. 39 Clutch Cable Clip
INPUT SHAFT FRONT BEARING RETAINER
REMOVAL
(1) Remove the transaxl e assembl y from the vehi -
cl e. For removal procedure, refer to Transaxl e,
Removal and I nstal l ati on.
(2) From i nsi de the bel l housi ng, remove the E-cl i p
retai ni ng the cl utch rel ease l ever shaft (Fi g. 43).
(3) Pul l rel ease l ever shaft out of the cl utch bel l -
(4) Remove the cl utch rel ease beari ng from the
i nput beari ng retai ner sl eeve (Fi g. 45).
(5) Remove the three bol ts retai ni ng the i nput
shaft beari ng retai ner sl eeve (Fi g. 46).
(6) Remove the i nput beari ng retai ner sl eeve from
the front of the bel l housi ng.
INSTALLATION
Use Mopar Gasket Maker to seal i nput beari ng
retai ner sl eeve to bel l housi ng.
Fig. 40 Front Engine Mount (Left Side)
Fig. 41 Front Engine Mount (Right Side)
Fig. 42 Left Mount Bolts
(2) Ti ghten the i nput beari ng retai ner sl eeve bol ts
to 28 Nm (250 i n. l bs.).
INPUT SHAFT SEAL
REMOVAL
(1) Remove i nput shaft front beari ng retai ner from
transaxl e case. Refer to I nput Beari ng Retai ner
Removal i n thi s group.
(2) Pl ace the retai ner i n a soft-jawed vi se.
(3) Usi ng a fl at-bl ade pry tool , remove the i nput
shaft seal from the retai ner.
INSTALLATION
(1) Posi ti on the new i nput shaft seal i n the
retai ner.
(2) Pl ace the retai ner on a fl at surface (seal si de
down).
(3) Push down on beari ng retai ner to i nstal l seal
(Fi g. 47).
(4) I nstal l i nput beari ng retai ner. Refer to I nput
Beari ng Retai ner I nstal l ati on i n thi s group.
A-558 TRANSAXLE ASSEMBLY RHD VEHICLES
REMOVAL
(2) Remove ai r i ntake hose.
(3) Remove connector for back-up l amp (Fi g. 48).
(4) Remove wi ri ng harness bracket at transaxl e
(Fi g. 49).
(5) Unbol t sl ave cyl i nder and actuator rod at the
transaxl e (Fi g. 50).
(6) I nstal l engi ne support fi xture and chai n onto
engi ne (Fi g. 51) and (Fi g. 52).
(7) Remove cover from accel erator cabl es at throt-
tl e body (Fi g. 53).
(8) Remove throttl e body to transaxl e bracket (Fi g.
54).
(9) Remove two (2) upper transaxl e nuts/studs
(Fi g. 54).
(10) Remove crossover and shi ft sel ector cabl es
(Fi g. 55).
(11) Li ft the vehi cl e on hoi st.
Fig. 46 Input Bearing Retainer
Fig. 47 Install Seal
Fig. 48 Back-up Lamp Connector
Fig. 49 Wiring Harness Bracket
Fig. 50 Hydraulic Clutch Linkage
Fig. 51 Engine Bridge Fixture
(12) Remove the front wheel s.
(13) Remove the two (2) axl e shaft hub nuts.
(14) Remove three upper bel l housi ng bol ts.
(15) Remove steeri ng stop studs at steeri ng knuck-
l es.
(16) Remove l ower control arm pi nch bol ts (Fi g.
56).
(17) Usi ng a pry bar, unseat l ower control arm
from steeri ng knuckl e (Fi g. 57).
(18) Remove drai n pl ug and drai n transaxl e fl ui d
(Fi g. 58).
(19) Remove ri ght and l eft axl e shaft assembl i es
(20) Remove vehi cl e speed sensor wi ri ng connector
(Fi g. 59).
(21) Remove structural brace from engi ne and
transaxl e.
Fig. 52 Engine Support Chain Typical
Fig. 53 Throttle Control Shield
Fig. 54 Throttle Control Support Bracket
Fig. 55 Shift Cables
Fig. 56 Lower Control Arm Pinch Bolt
(22) Remove l ower starter bol t.
(23) Remove engi ne wi ri ng harness cl i p.
CAUTION: Always use a safety chain when remov-
ing or installing transaxle assembly.
(24) Pl ace a transmi ssi on jack under the transmi s-
si on
(25) Remove the transaxl e l ower dust cover.
(26) Remove the access cover i n ri ght spl ash shi el d
to access torsi onal damper bol t.
(27) Remove dri ve pl ate to modul ar cl utch bol ts
whi l e hol di ng torsi onal damper bol t wi th socket and
ratchet. To avoi d di storti on of the dri ve pl ate, remove
the modul ar cl utch bol ts a few turns at a ti me. Use a
cri sscross pattern unti l al l bol ts are l oosened.
(28) Unbol t rear engi ne mount through bol t and
two (2) mount bol ts.
(29) Remove the l eft front fender spl ash shi el d.
(30) Unbol t l eft engi ne mount through bol t and
unbol t mount from the transaxl e.
(31) Remove front engi ne mount (Fi g. 60) and (Fi g.
61).
(32) Lower the transaxl e and modul ar cl utch.
To servi ce the dri ve pl ate, refer to Group 9, Engi ne.
INSTALLATION
(1) Posi ti on the modul ar cl utch assembl y onto the
i nput shaft of the transaxl e (Fi g. 62).
(2) To rei nstal l transaxl e, reverse removal proce-
dure maki ng certai n to al i gn the el ongated hol e i n
the dri ve pl ate wi th the modul ar cl utch bol t hol e that
has the whi te pai nt mark.
Fig. 57 Unseat Control Arm
Fig. 60 Front Engine Mount (Left Side)
NOTE: To avoid distortion of the drive plate, bolts
should be tightened a few turns at a time. Use a
crisscross pattern until all bolts are seated. Tighten
modular clutch plate bolts to 74 Nm (55 ft. lbs.).
NOTE: Lower control arm pinch bolts must be
installed with the bolt head rearward of the ball
joint.
TRANSAXLE
The A-598 transaxl e (Fi g. 63) i s si mi l ar to the
A-523, A-568 transaxl e wi th the fol l owi ng excepti ons.
The major di fferences are that the i nput shaft i s sup-
ported by bal l and rol l er beari ngs and the i ntermedi -
ate shaft i s supported by tapered rol l er beari ngs.
Al so the front i ntermedi ate beari ng wi l l not cl ear the
fi nal dri ve gear for di sassembl y or reassembl y.
I n vehi cl e servi ce i s l i mi ted to:
Shi ft cover components
Seal i ng external joi nts and seal s
Servi ce of 5th gear set and synchroni zer
DISASSEMBLY
(1) Remove engi ne mount bracket (Fi g. 64).
(2) Remove di fferenti al beari ng retai ner (Fi g. 65).
(3) Remove extensi on housi ng (Fi g. 66).
(4) Remove di fferenti al cover wi th soft-faced ham-
mer (Fi g. 67).
Fig. 62 Modular Clutch Mounting
Fig. 61 Front Engine Mount (Right Side)
Fig. 63 A-598 Transaxle
(5) Remove di fferenti al assembl y (Fi g. 68) (Fi g.
69).
CAUTION: Shift detent springs are located under-
neath shift cover. Remove shift cover carefully.
(6) Remove shi ft cover (Fi g. 70) (Fi g. 72).
Fig. 64 Engine Mount Bracket
Fig. 66 Extension Housing
Fig. 67 Differential Cover
Fig. 68 Differential
Fig. 69 Differential Components
NOTE: Two of the bolts retaining the shift cover are
shouldered. Mark the bolts and the location (Fig.
71).
(7) Remove shi ft cover spl ash shi el d (Fi g. 73).
(8) Remove shi ft detent spri ngs (Fi g. 74) and rol l -
ers (Fi g. 75).
NOTE: On some A-598 transaxles all four detent
springs are of the same color and spring tension.
On other A-598 transaxles, three identical springs
are used on the forward gear detents, while the
reverse detent spring is a different tension and
color.
(9) Remove reverse pi vot l ever actuator arm (Fi g.
76).
(10) Remove 12 rol l pi n at 12 shi ft fork (Fi g. 77).
(11) Rotate 12 shi ft l ug out of the way.
(12) Remove 34 rol l pi n at 34 shi ft l ug (Fi g. 78).
(13) Remove 5th gear/synchro end cover (Fi g. 79)
(Fi g. 80).
Fig. 70 Gearshift Cover
Fig. 71 Gearshift Cover Shouldered Bolts
Fig. 72 Shift Cover Removed
Fig. 73 Shift Cover Splash Shield
Fig. 74 Shift Detent Springs
(14) Remove 5th gear shi ft fork rol l pi n (Fi g. 81).
(15) Remove snap ri ng at 5th gear synchro (Fi g.
82).
(16) Remove 5th gear shi ft fork, synchro pl ate, and
synchro (Fi g. 83) (Fi g. 84).
(17) Use Speci al Tool #6252 to hol d 5th gear and
remove 5th gear nut (Fi g. 85) at i nput shaft .
Fig. 75 Shift Detent Rollers
Fig. 76 Reverse Pivot Lever Actuator Arm
Fig. 77 12 Shift Fork Roll Pin
Fig. 78 34 Shift Lug Roll Pin
Fig. 79 End Cover
Fig. 80 End Cover Removed
(18) Remove 5th gear (Fi g. 86).
(19) Remove beari ng retai ner pl ate bol ts (Fi g. 87).
(20) Remove beari ng retai ner pl ate (Fi g. 88) (Fi g.
89).
(21) Remove prel oad shi m at i ntermedi ate shaft
(Fi g. 90).
Fig. 81 5th Gear Shift Fork Roll Pin
Fig. 82 5th Gear Synchronizer Snap Ring
Fig. 83 5th Gear Shift Fork, Rail, and Synchronizer
Removed
Fig. 85 5th Gear Retaining Nut
Fig. 86 5th Gear
(22) Remove i nput shaft beari ng snap ri ng (Fi g.
91) (Fi g. 92).
(23) Remove i nterl ock pl ate (Fi g. 93) and shuttl es
(Fi g. 94).
NOTE: The shift rails are positioned as shown (Fig.
95).
Fig. 87 Bearing Retainer Plate Bolts
Fig. 88 Bearing Retainer Plate
Fig. 89 Retainer Plate Removed
Fig. 90 Bearing Preload Shim
Fig. 91 Input Shaft Bearing Snap Ring
Fig. 92 Snap Ring Removed
(24) Remove beari ng support pl ate (Fi g. 96) (Fi g.
97).
(25) Remove reverse i dl er gear (Fi g. 98) (Fi g. 99).
(26) Remove 5th gear shi ft rai l C-cl i p (Fi g. 100).
CAUTION: The 5th gear shift rail has a small inter-
lock pin that is contained within the shift lug and
rail. Use caution when removing shift rail.
Fig. 93 Interlock Plate
Fig. 94 Shuttles
Fig. 95 Shift Rail Identification
Fig. 96 Bearing Support Plate
Fig. 97 Support Plate Removed
Fig. 98 Reverse Idler Gear
(27) Careful l y remove 5th gear shi ft rai l (Fi g. 101)
(Fi g. 102) (Fi g. 103).
(28) Remove reverse shi ft rai l (Fi g. 104) (Fi g. 105).
(29) Move the 12 and 34 shi ft rai l l ugs out of
the way (Fi g. 106).
(30) Remove geartrai n set (Fi g. 107).
Fig. 99 Reverse Idler Removed
Fig. 100 Shift Rail C-clip
Fig. 101 5th Gear Shift Rail
Fig. 102 5th Gear Shift Rail Removed
Fig. 103 5th Gear Shift Rail, Interlock, and Pin
Fig. 104 Reverse Shift Rail
NOTE: The input shaft is serviced as an assembly.
The only serviceable components of the input shaft
are the bearings.
To di sassembl e the i ntermedi ate shaft, di fferenti al ,
synchroni zers, or transaxl e case, refer to the appro-
pri ate procedure i n thi s secti on (Fi g. 108).
ASSEMBLY
I f the transaxl e housi ng, i ntermedi ate shaft, bear-
i ng pl ate, or beari ngs were repl aced, you must adjust
the i ntermedi ate shaft beari ng prel oad. To adjust
i ntermedi ate shaft prel oad, refer to I ntermedi ate
Shaft Prel oad Adjustment.
(1) I nstal l geartrai n set.
CAUTION: The 5th gear shift rail has a small inter-
lock pin that is contained within the shift lug and
rail. Use caution when installing shift rail.
(2) Careful l y i nstal l 5th gear shi ft rai l (Fi g. 109)
(Fi g. 110).
(3) I nstal l 5th gear shi ft rai l C-cl i p.
(4) I nstal l reverse shi ft rai l .
(5) I nstal l reverse i dl er gear (Fi g. 111).
Fig. 105 Reverse Shift Rail Removed
Fig. 106 Reposition Shift Rail Lugs
Fig. 107 Geartrain Removal
Fig. 108 Geartrain Components
Fig. 109 5th Gear Shift Rail and Interlock
NOTE: Verify that the rear oil trough is properly
installed and retained in the bearing support plate
before installing support plate.
(6) Appl y a bead of Mopar Gasket Maker or
equi val ent onto beari ng support pl ate. I nstal l beari ng
support pl ate (Fi g. 112).
(7) I nstal l i nterl ock pl ate (Fi g. 113) and shuttl es
(Fi g. 114).
(8) I nstal l i nput shaft beari ng snap ri ng (Fi g. 115).
(9) I nstal l prel oad shi m at i ntermedi ate shaft (Fi g.
116).
(10) I nstal l beari ng retai ner pl ate. Ti ghten beari ng
retai ner pl ate to 17 Nm (250 i n. l bs.).
NOTE: If the transaxle housing, intermediate shaft,
bearing retainer plate, or bearings are replaced, you
must perform the intermediate shaft bearing pre-
load procedure. Refer to Intermediate Shaft Bearing
Preload Adjustment procedure in the ADJUST-
MENTS section.
(11) I nstal l 5th gear.
(12) Use Speci al Tool 6252 to hol d 5th gear and
i nstal l 5th gear nut at i nput shaft. Ti ghten the
retai ni ng nut to 176 Nm (130 ft. l bs.).
Fig. 110 5th Gear Shift Rail
Fig. 111 Reverse Idler Gear
Fig. 112 Support Plate
Fig. 113 Interlock Plate
Fig. 114 Shuttles
(13) Use Speci al Tool 6930 to stake the 5th gear
retai ni ng nut onto the i nput shaft (Fi g. 117).
(14) I nstal l 5th gear shi ft fork, synchro, and pl ate
(Fi g. 118).
(15) I nstal l snap ri ng at 5th gear synchro (Fi g.
119).
(16) I nstal l 5th gear shi ft fork rol l pi n (Fi g. 120).
Fig. 115 Input Shaft Bearing Snap Ring
Fig. 117 Staking 5th Gear Retaining Nut
equi val ent onto end cover. I nstal l 5th gear/synchro
end cover. Ti ghten bol ts to 28 Nm (250 i n. l bs.).
(18) Move 34 shi ft l ug i nto posi ti on. I nstal l 34
rol l pi n at 34 shi ft l ug (Fi g. 121).
(19) I nstal l 12 rol l pi n at 12 shi ft fork (Fi g. 122).
(20) I nstal l reverse pi vot l ever actuator arm (Fi g.
123).
NOTE: When installing shift detents, align the
detent slots in line with the longitudinal axis of the
transaxle (same direction as the shift rails).
NOTE: On some A-598 transaxles all four detent
springs are of the same color and spring tension.
On other A-598 transaxles, three identical springs
are used on the forward gear detents, while the
reverse detent spring is a different tension and
color.
(21) I nstal l shi ft detents, spri ngs, and rol l ers (Fi g.
124) (Fi g. 125).
(22) I nstal l shi ft cover spl ash shi el d (Fi g. 126).
Fig. 121 34 Shift Lug Roll Pin
Fig. 122 12 Shift Fork Roll Pin
Fig. 123 Reverse Pivot Lever Actuator Arm
Fig. 124 Shift Detent Rollers
Fig. 125 Shift Detent Springs
NOTE: Two of the bolts retaining the shift cover are
shouldered (Fig. 127).
equi val ent onto shi ft cover. Li ne up the shi ft detent
spri ngs so the spri ngs are al i gned wi th the shi ft
cover spri ng pockets. I nstal l shi ft cover. Ti ghten shi ft
cover bol ts to 28 Nm (250 i n. l bs.).
(24) I nstal l di fferenti al assembl y.
equi val ent onto di fferenti al cover. I nstal l di fferenti al
cover. Ti ghten di fferenti al cover bol ts to 61 Nm (45
ft. l bs.).
(26) Appl y a bead of RTV si l i cone to the di fferen-
ti al beari ng retai ner. I nstal l di fferenti al beari ng
retai ner. Ti ghten di fferenti al beari ng retai ner bol ts to
61 Nm (45 ft. l bs.).
(27) Appl y a bead of RTV si l i cone to the extensi on
housi ng. I nstal l extensi on housi ng. Ti ghten extensi on
housi ng bol ts to 28 Nm (250 i n. l bs.).
(28) I nstal l engi ne mount bracket.
INPUT SHAFT
The i nput shaft i s servi ced as an assembl y. The
onl y servi ceabl e component of the i nput shaft i s the
rear beari ng.
DISASSEMBLY
(1) I nstal l the beari ng spl i tter 1130 under the rear
beari ng.
(2) Posi ti on the i nput shaft i nto a shop press (Fi g.
128).
(3) Remove the rear beari ng (Fi g. 129).
ASSEMBLY
(1) Posi ti on repl acement beari ng onto the i nput
shaft (Fi g. 130).
(2) Pl ace i nput shaft i nto shop press.
(3) Posi ti on Speci al Tool 6950 over i nput shaft on
top of beari ng.
(4) Press i nput shaft beari ng i nto posi ti on (Fi g.
131).
Fig. 126 Shift Cover Splash Shield
Fig. 127 Gearshift Cover Shouldered Bolts
Fig. 128 Input Shaft
Fig. 129 Remove Bearing
INTERMEDIATE SHAFT
DISASSEMBLY
(1) I nstal l i ntermedi ate shaft i nto shop press.
(2) I nstal l beari ng spl i tter 1130 under the 4th
speed gear cl utch teeth (Fi g. 132).
(3) Remove i ntermedi ate shaft rear beari ng snap
ri ng (Fi g. 133).
(4) Posi ti on Speci al Tool 67921 over i ntermedi ate
shaft.
CAUTION: To prevent damaging the intermediate
shaft, grasp the bottom of the shaft when doing
shop press procedures.
(5) Usi ng Speci al Tool 67921 as a dri ver, press off
and remove 4th speed gear (Fi g. 134).
(6) Remove i ntermedi ate shaft from shop press.
(7) I nstal l Speci al Tool 6938 onto front i ntermedi -
ate beari ng for protecti on.
(8) Remove 34 synchro snap ri ng (Fi g. 135) (Fi g.
136).
NOTE: The 34 synchro has a master spline (Fig.
137).
Fig. 130 Position Bearing
Fig. 131 Press Input Bearing Onto Shaft
Fig. 132 Bearing Splitter Installed
Fig. 133 Intermediate Shaft Rear Bearing Snap Ring
Fig. 134 Press Off 4th Speed Gear
(9) Remove 34 synchro assembl y and 3rd speed
gear (Fi g. 138).
(10) Remove thrust washer outer retai ner (Fi g.
139).
(11) Remove the two spl i t washers.
(12) Remove the anti -spi n pi n (Fi g. 140).
(13) Remove 2nd speed gear (Fi g. 141).
(14) Remove 12 synchro snap ri ng (preci si on
ground) (Fi g. 142) (Fi g. 143).
Fig. 135 34 Synchro Snap Ring
Fig. 137 Master Spline
Fig. 139 Thrust Washer Outer Retainer
Fig. 138 34 Synchro and 3rd Speed Gear
Fig. 140 Anti-Spin Pin
Fig. 141 2nd Speed Gear
(15) Remove 12 dual cone synchro assembl y and
1st speed gear (Fi g. 144).
(16) I nstal l Speci al Tool 1130 beari ng spl i tter
under the pl asti c i ntermedi ate shaft front beari ng
(17) Posi ti on shaft i nto shop press.
(18) Posi ti on Speci al Tool MD99880201 over the
i ntermedi ate shaft.
(19) Remove the i ntermedi ate shaft front beari ng
(Fi g. 145).
Fig. 144 12 Dual Cone Synchro
ASSEMBLY
(1) Posi ti on i ntermedi ate shaft front beari ng onto
i ntermedi ate shaft. I nstal l Speci al Tool 6938 over
beari ng and shaft. I nstal l the i ntermedi ate shaft
front beari ng (Fi g. 146).
(2) Remove i ntermedi ate shaft from shop press.
(3) Posi ti on i ntermedi ate shaft beari ng si de down.
Pl ace i ntermedi ate shaft i nto Speci al Tool 6938 to
protect front beari ng. I nstal l 12 dual cone synchro
assembl y and 1st speed gear.
(4) I nstal l 12 synchro snap ri ng (preci si on
ground) (Fi g. 147).
(5) I nstal l 2nd speed gear (Fi g. 148).
(6) I nstal l the anti -spi n pi n (Fi g. 149).
(7) I nstal l the two spl i t washers.
(8) I nstal l thrust washer outer retai ner (Fi g. 150).
NOTE: The 34 synchro has a master spline (Fig.
151).
(9) I nstal l 34 synchro assembl y and 3rd speed
gear.
(10) I nstal l 34 synchro snap ri ng (Fi g. 152).
(11) I nstal l 4th speed gear over the 34 synchro.
Fig. 145 Intermediate Shaft Front Bearing
Fig. 146 Install Intermediate Shaft Front Bearing
Fig. 148 2nd Speed Gear
Fig. 151 Master Spline Fig. 149 Anti-Spin Pin
Fig. 150 Thrust Washer Outer Retainer
(12) Posi ti on the i ntermedi ate shaft rear beari ng
onto the i ntermedi ate shaft.
(13) I nstal l the i ntermedi ate shaft i nto a shop
press.
(14) Posi ti on Speci al Tool MD998323 over the
i ntermedi ate shaft rear beari ng
(15) Press on the i ntermedi ate shaft rear beari ng
(Fi g. 153).
(16) I nstal l i ntermedi ate shaft rear beari ng snap
ri ng.
DIFFERENTIAL
NOTE: The differential is typically serviced as an
assembly. The only parts that are serviceable within
the differential are the differential bearing cups and
cones. If any other part fails within the differential,
you should replace the differential assembly.
Transaxl e gear case
Di fferenti al case
Di fferenti al beari ngs
Di fferenti al cover
Refer to Bearing Adjustment Procedure i n the
Adjustments secti on at the end of thi s secti on to
determi ne proper shi m thi ckness. Thi s wi l l provi de
correct beari ng prel oad and proper beari ng turni ng
torque.
DIFFERENTIAL BEARINGS
Di fferenti al beari ngs are usual l y servi ced as pai rs.
I f one di fferenti al beari ng fai l s, you shoul d repl ace
both beari ng cups and cones
Fig. 153 Intermediate Shaft Rear Bearing Installation
.
Fig. 158 Remove Differential Bearing Retainer Cup
Fig. 160 Install Oil Baffle
Fig. 161 Insert (Select) Shim and Differential
Bearing Retainer Cup
Fig. 162 Remove Extension Bearing Cup
Fig. 163 Extension
Fig. 164 Install Extension Oil Baffle
RING GEAR
CAUTION: Always install new ring gear bolts.
Tighten ring gear bolts to 94 Nm (70 ft. lbs.) torque.
DIFFERENTIAL GEARS
REMOVAL
(1) Remove pi ni on shaft retai ni ng pi n (Fi g. 167)
(Fi g. 168).
(2) Remove pi ni on shaft (Fi g. 169).
(3) Rotate si de gears to openi ng i n di fferenti al
(Fi g. 170).
(4) Remove di fferenti al gears (Fi g. 171).
Fig. 165 Install Extension Bearing Cup
Fig. 166 Remove or Install Ring Gear Bolts and
Ring Gear
Fig. 167 Remove Pinion Shaft Retaining Pin
Fig. 168 Retaining Pin Removed
Fig. 169 Pinion Shaft Removal
INSTALLATION
(1) Assembl e the di fferenti al si de gears, pi ni on
gears and pi ni on gears wi th the pi ni on gear washers.
(2) I nstal l pi ni on shaft retai ni ng pi n (Fi g. 172).
(3) Stake pi ni on shaft retai ni ng pi n wi th a sui tabl e
chi sel (Fi g. 173).
(4) Rotate the assembl y two ful l revol uti ons both
cl ockwi se and countercl ockwi se. Set up di al i ndi cator
as shown and record end pl ay (Fi g. 174) (Fi g. 175).
Rotate si de gear 90 degrees and record another end
pl ay. Agai n, rotate si de gear 90 degrees and record a
fi nal end pl ay.
(5) Usi ng the smal l est end pl ay recorded, shi m
that si de gear to wi thi n .02540 mm to .3302 mm
(0.001 to 0.013 i nch). The other si de gear shoul d be
checked usi ng the same procedure.
CAUTION: Side gear end play must be within 02540
mm to .3302 mm (0.001 to 0.013 inch). Five select
thrust washers are available: 0.027, 0.032, 0.037,
0.042, and 0.047 inch.
SYNCHRONIZER
The 12 synchroni zer i s a dual -cone synchroni zer
(Fi g. 176). The di sassembl y and assembl y procedures
are the same as the 34 synchroni zer (Fi g. 177)
Fig. 171 Differential Gears
Fig. 170 Remove Pinion Gears, Side Gears, and
Thrust Washers by Rotating Side Gears to Opening
in Case
Fig. 172 Install Retaining Pin
except you must fi rst remove two i nner and outer
cones from the synchroni zer and stop ri ng assembl y.
DISASSEMBLY
(1) Pl ace the synchroni zer on a cl ean shop rag on a
tabl e.
(2) Remove the i nner cones (dual -cone synchro-
ni zer) from the outer cones.
(3) Remove the outer cones (dual -cone synchro-
ni zer) from the synchroni zer stop ri ngs.
(4) Remove the synchroni zer stop ri ngs.
(5) Remove the synchroni zer spri ngs on both si des
of the hub.
(6) Careful l y remove the synchro hub from the
synchro sl eeve.
(7) Remove the three struts from the hub.
ASSEMBLY
(1) I nsert the three struts i nto the synchro hub.
(2) Pl ace the hub i nto the synchro sl eeve.
NOTE: Stagger both synchronizer springs (install
tang in different winged struts).
Fig. 173 Staking Retaining Pin
Fig. 176 12 Synchronizer
Fig. 177 34 Synchronizer
(3) I nstal l the synchro spri ngs i nto the synchro
struts.
(4) Li ne up stop ri ng tang over the struts i n the
hub. I nstal l stop ri ngs. Center the struts by pushi ng
on both stop ri ngs.
(5) I nstal l the outer cones (dual -cone synchroni zer)
i nto the synchroni zer stop ri ngs.
(6) I nstal l the i nner cones (dual -cone synchroni zer)
i nto the outer cones.
SHIFT COVER
The gearshi ft cover can be di sassembl ed and worn
parts can be repl aced i ndi vi dual l y (Fi g. 178).
DISASSEMBLY
(1) Remove gearshi ft housi ng rol l pi n at shi ft l ever
(Fi g. 179).
(2) Remove shi ft sel ector shaft dust boot (Fi g. 180).
(3) Remove sel ector shaft oi l seal (Fi g. 181).
(4) Remove shi fter housi ng vent cap at crossover
l ever (Fi g. 182).
(5) Remove rol l pi n and crossover l ever at cross-
over shaft (Fi g. 183).
(6) Remove the 5th/reverse gear bl ocker (Fi g. 184).
(7) Remove the crossover shaft (Fi g. 185).
Fig. 178 Gearshift Housing-Exploded View
Fig. 179 Shift Lever Roll Pin
(8) Remove sel ector shaft i nner C-cl i p (Fi g. 186).
(9) Remove sel ector shaft outer C-cl i p (Fi g. 187).
Fig. 180 Dust Boot
Fig. 181 Oil Seal
Fig. 182 Vent Cap
Fig. 183 Crossover Lever and Roll Pin
Fig. 184 5th/Reverse Blocker
Fig. 185 Crossover Shaft
NOTE: Drive roll pin out far enough to clear the
selector shaft, but not through. The pin must
remain in the selector so not to break the housing.
(10) Remove sel ector shaft center rol l pi n (Fi g.
188).
(11) Remove sel ector shaft from the shi ft housi ng
(Fi g. 189) (Fi g. 190).
ASSEMBLY
(1) I nstal l sel ector shaft components and sel ector
shaft i nto shi ft housi ng.
(2) I nstal l sel ector shaft rol l pi n fl ush wi th sel ec-
tor.
(3) I nstal l outer sel ector shaft C-cl i p.
(4) I nstal l i nner sel ector shaft C-cl i p.
(5) I nstal l crossover shaft.
NOTE: Proper torque of the 5-R blocker bolts is
very important.
(6) I nstal l the 5th/reverse gear bl ocker bol ts (Fi g.
191).
(7) I nstal l rol l pi n and crossover l ever at crossover
shaft
(8) I nstal l vent cap.
Fig. 186 Inner C-clip
Fig. 187 Outer C-clip
Fig. 188 Center Roll Pin
Fig. 189 Selector Shaft Removal
Fig. 190 Selector Shaft Components
NOTE: The C-Clip grooves in the selector shaft will
damage the oil seal. Install oil seal after selector
shaft is installed. Always use a new oil seal when
selector shaft is removed.
(9) I nstal l sel ector shaft oi l seal (Fi g. 192).
(10) I nstal l sel ector shaft dust boot.
(11) I nstal l sel ector shaft sel ector l ever.
NOTE: Roll pin must be flush with top of lever.
TRANSAXLE CASE
INTERMEDIATE SHAFT FRONT BEARING CUP
REMOVAL
(1) I nsert Speci al Tool 6787 i nto the i ntermedi ate
shaft front beari ng cup (Fi g. 193).
(2) Ti ghten the speci al tool so that the tool fi ngers
spread out and seat underneath the beari ng cup.
(3) I nstal l Speci al Tool 3752 (Sl i de Hammer) onto
the Speci al Tool 6787.
(4) Remove the i ntermedi ate shaft front beari ng
cup (Fi g. 194).
(5) Remove the beari ng oi l feeder (i f necessary).
INSTALLATION
(1) I nsert the beari ng oi l feeder (i f necessary) i nto
the transaxl e case (Fi g. 195).
Fig. 191 5R Blocker Bolts
Fig. 192 Selector Shaft Oil Seal
Fig. 193 Special Tool 6787 Installed in Bearing Cup
Fig. 194 Remove Intermediate Shaft Front Bearing
Cup
(2) Veri fy the oi l feeder i s centered wi thi n the
beari ng bore.
(3) Posi ti on the beari ng cup i nto the beari ng bore.
(4) Posi ti on Speci al Tool 6939 and Speci al Tool
C-4171 i nto the i ntermedi ate shaft beari ng cup.
(5) Press new beari ng cup i nto the case (Fi g. 196).
INPUT SHAFT FRONT BEARING
REMOVAL
(1) From i nsi de the bel l housi ng, remove the E-cl i p
retai ni ng the cl utch rel ease l ever shaft (Fi g. 197).
(2) Pul l rel ease l ever shaft out of the cl utch bel l -
(3) Remove the cl utch rel ease beari ng from the
i nput beari ng retai ner sl eeve (Fi g. 199).
(4) Remove the three bol ts retai ni ng the i nput
shaft beari ng retai ner sl eeve (Fi g. 200).
(5) Remove the i nput beari ng retai ner sl eeve from
the front of the bel l housi ng (Fi g. 201).
(6) Posi ti on transaxl e case i n a shop press (bel l -
housi ng si de down).
(7) I nstal l Speci al Tool 5066 i nto i nput beari ng.
(8) I nstal l Speci al Tool C-4171 i nto Speci al Tool
5066
(9) Press out the i nput beari ng from the case (Fi g.
202).
Fig. 196 Install Intermediate Shaft Bearing Front
Bearing Cup
Fig. 195 Install Bearing Oil Feeder
INSTALLATION
(1) Posi ti on new i nput beari ng i nto the transaxl e
case (Fi g. 203).
(2) Posi ti on transaxl e case i n shop press (bel l hous-
i ng si de up).
(3) I nstal l Speci al Tool 6933 i nto i nput beari ng
(Fi g. 204).
(4) I nstal l Speci al Tool C-4171 i nto Speci al Tool
6933.
(5) Press i nput beari ng i nto transaxl e case (Fi g.
205).
Fig. 200 Input Bearing Retainer
Fig. 201 Remove Input Bearing Retainer
Fig. 202 Press Out Input Bearing
Fig. 203 Input Bearing
(6) Appl y a smal l bead of Mopar gasket Maker to
the i nput beari ng retai ner.
(7) I nstal l beari ng retai ner.
(8) I nstal l cl utch rel ease fork onto cl utch rel ease
beari ng.
(9) I nstal l beari ng and fork onto i nput beari ng
retai ner sl eeve.
(10) I nstal l cl utch rel ease shaft bushi ngs i nto tran-
saxl e case.
(11) I nstal l cl utch rel ease shaft i nto case and
i nstal l E-cl i p onto shaft (Fi g. 206).
SHIFT RAIL BUSHINGS
REMOVAL
(1) I nstal l Speci al Tool 6786 i nto rai l bushi ng that
i s to be removed (Fi g. 207).
(2) Ti ghten tool unti l the tool i s thoroughl y i mbed-
ded i nto the bushi ng.
(3) I nstal l Speci al Tool 3752 (Sl i de Hammer) i nto
Speci al Tool 6786 (Fi g. 208).
(4) Tap out shi ft rai l bushi ng (Fi g. 209).
INSTALLATION
(1) Lubri cate outer shel l of the shi ft rai l bushi ng.
(2) Posi ti on shi ft rai l bushi ng i nto the shi ft rai l
bore.
(3) Tap bushi ng i nto the bore, fl ush wi th the bore
face
Fig. 204 Special Tool 6933
Fig. 205 Press Input Bearing Into Case
Fig. 207 Special Tool 6786
REVERSE SHIFT LEVER
REMOVAL
(1) Remove reverse shi ft l ever E-cl i p.
(2) Remove the fl at and wave washers.
(3) Remove the reverse shi ft l ever from the mount-
i ng stud.
INSTALLATION
(1) Posi ti on the reverse shi ft l ever onto the mount-
i ng stud.
(2) I nstal l the washers onto the mounti ng stud.
(3) I nstal l the E-cl i p.
TRANSAXLE
Cl ean the gears, beari ngs, shafts, synchroni zers,
thrust washers, oi l feeder, shi ft mechani sm, gear
case, and bel l housi ng wi th sol vent. Dry al l parts
except the beari ngs wi th compressed ai r. Al l ow the
beari ngs to ei ther ai r dry or wi pe them dry wi th
cl ean shop towel s.
I nspect the gears, beari ngs, shafts and thrust
washers. Repl ace the beari ngs and cups i f the rol l ers
are worn, chi pped, cracked, fl at spotted, or bri n-
nel l ed, or i f the beari ng cage i s damaged or di storted.
Repl ace the thrust washers i f cracked, chi pped, or
worn. Repl ace the gears i f the teeth are chi pped,
cracked, or worn thi n. I nspect the synchroni zers.
Repl ace the sl eeve i f worn or damaged i n any way.
Repl ace the stop ri ngs i f the fri cti on materi al i s
burned, fl aki ng off, or worn. Check the condi ti on of
the synchro struts and spri ngs. Repl ace these parts i f
worn, cracked, or di storted.
SYNCHRONIZER
CLEAN
Do not attempt to cl ean the bl ocki ng ri ngs i n sol -
vent. The fri cti on materi al wi l l become contami nated.
Pl ace synchroni zer components i n a sui tabl e hol der
and cl ean wi th sol vent. Ai r dry.
INSPECT
Proper i nspecti on of components i nvol ve:
Teeth, for wear, scuffed, ni cked, burred, or bro-
ken teeth
Struts, for wear or di storti on
Spri ngs, for di storti on, cracks, or wear
I f any of these condi ti ons exi st i n these compo-
nents, repl ace as necessary.
ADJ USTMENTS
GEARSHIFT CROSSOVER CABLE
Before repl aci ng the gearshi ft cabl es for a hard-
shi fti ng compl ai nt, di sconnect both cabl es at the
transaxl e. Then, from the dri vers seat, manual l y
operate the gearshi ft l ever through al l gear ranges. I f
the gearshi ft l ever moves smoothl y, the cabl e(s)
shoul d NOT be repl aced. I f the gear l ever bi nds
repl ace the cabl e that i s causi ng the bi ndi ng condi -
ti on. I f the probl em sti l l exi sts, check the crossover
cabl e adjustment (Fi g. 210).
(1) Worki ng over the l eft front fender, remove the
auxi l i ary vent from the sel ector shaft housi ng (Fi g.
211).
(2) Locate the gearshi ft l ock pi n that has been
i ncl uded i n the new vehi cl e packet l ocated i n the
gl ove box.
(3) Pl ace transaxl e gearshi ft i n the neutral posi -
ti on.
(4) I nsert l ock pi n (so l ong end i s down) i nto same
threaded hol e (Fi g. 212). A hol e i n the sel ector shaft
wi l l al i gn wi th the l ock pi n, al l owi ng the l ock pi n to
Fig. 208 Slide Hammer 3752
Fig. 209 Shift Rail Bushing Removal
be screwed i nto the housi ng. Thi s operati on l ocks the
sel ector shaft i n the 3-4 neutral posi ti on.
(5) Remove gearshi ft knob (Fi g. 213).
(6) Remove gearshi ft boot (Fi g. 214).
(7) Remove gearshi ft consol e screws and remove
the consol e (Fi g. 215).
(8) Loosen crossover cabl e adjustment screw.
(9) Veri fy gearshi ft mechani sm i s i n the neutral
posi ti on.
CAUTION: Be sure crossover bellcrank does NOT
move when tightening adjusting screw.
Fig. 210 Gearshift Mechanism
Fig. 211 Auxiliary Vent Removal
Fig. 212 Lock Pin Installation
(10) Ti ghten crossover cabl e adjuster to 8 Nm (70
i n. l bs.) (Fi g. 216).
CAUTION: Proper torque to the crossover cable
adjusting screw is very important.
(11) Remove l ock pi n from gearshi ft housi ng. Rei n-
stal l auxi l i ary vent i n gear shi ft housi ng (Fi g. 217).
Ti ghten auxi l i ary vent to 8 Nm (70 i n. l bs.).
(12) Check for shi ft i nto fi rst and reverse.
(13) Gearshi ft mechani sm and cabl es are now
functi oni ng properl y.
(14) I nstal l gearshi ft consol e.
(15) I nstal l gearshi ft boot.
(16) I nstal l gearshi ft knob.
(17) Stow gearshi ft l ock pi n i n gl ove packet.
Fig. 213 Gearshift Knob
Fig. 216 Crossover Cable Adjustment
Fig. 217 Auxiliary Vent Installation
GEARSHIFT CROSSOVER CABLE
Before repl aci ng the gearshi ft cabl es for a hard-
shi fti ng compl ai nt, di sconnect both cabl es at the
transaxl e. Then, from the dri vers seat, manual l y
operate the gearshi ft l ever through al l gear ranges. I f
the gearshi ft l ever moves smoothl y, the cabl e(s)
shoul d NOT be repl aced. I f the gear l ever bi nds
repl ace the cabl e that i s causi ng the bi ndi ng condi -
ti on. I f the probl em sti l l exi sts, check the crossover
cabl e adjustment (Fi g. 218).
(1) Worki ng over the l eft front fender, remove the
auxi l i ary vent from the sel ector shaft housi ng (Fi g.
219).
(2) Locate the gearshi ft l ock pi n that has been
i ncl uded i n the new vehi cl e packet l ocated i n the
gl ove box.
(3) Pl ace transaxl e gearshi ft i n the neutral posi -
ti on.
(4) I nsert l ock pi n (so l ong end i s down) i nto same
threaded hol e (Fi g. 220). A hol e i n the sel ector shaft
wi l l al i gn wi th the l ock pi n, al l owi ng the l ock pi n to
be screwed i nto the housi ng. Thi s operati on l ocks the
sel ector shaft i n the 3-4 neutral posi ti on.
(5) Remove gearshi ft knob (Fi g. 221).
(6) Remove gearshi ft boot (Fi g. 222).
(7) Remove gearshi ft consol e screws and remove
the consol e (Fi g. 223).
(8) Loosen crossover cabl e adjustment screw.
(9) Veri fy gearshi ft mechani sm i s i n the neutral
posi ti on.
CAUTION: Be sure crossover bellcrank does NOT
move when tightening adjusting screw.
Fig. 218 Gearshift Mechanism
Fig. 219 Auxiliary Vent Removal
(10) Ti ghten crossover cabl e adjuster to 8 Nm (70
i n. l bs.) (Fi g. 224).
CAUTION: Proper torque to the crossover cable
adjusting screw is very important.
(11) Remove l ock pi n from gearshi ft housi ng. Rei n-
stal l auxi l i ary vent i n gear shi ft housi ng (Fi g. 225).
Ti ghten auxi l i ary vent to 8 Nm (70 i n. l bs.).
(12) Check for shi ft i nto fi rst and reverse.
(13) Gearshi ft mechani sm and cabl es are now
functi oni ng properl y.
(14) I nstal l gearshi ft consol e.
(15) I nstal l gearshi ft boot.
(16) I nstal l gearshi ft knob.
(17) Stow gearshi ft l ock pi n i n gl ove packet.
BEARING ADJUSTMENT PROCEDURE
The A-598 (T-750) transaxl e has two beari ng
adjustment procedures that must be performed i f the
transaxl e case or rel ated components have been
repl aced. I f the i ntermedi ate shaft, and/or beari ng
cups and cones have been repl aced, you must per-
form the i ntermedi ate shaft prel oad shi m adjust-
ment. I f the di fferenti al case, cups or cones have
Fig. 220 Lock Pin Installation
Fig. 221 Gearshift Knob
been repl aced, you must perform the di fferenti al
beari ng prel oad shi m adjustment. I f the transaxl e
case has been repl aced, you must perform both pro-
cedures.
GENERAL RULES ON SERVICING BEARINGS
(1) Use extreme care when removi ng and i nstal l -
i ng beari ng cups and cones. Burrs or ni cks on the
beari ng seat wi l l gi ve a fal se end pl ay readi ng whi l e
gaugi ng for proper shi ms. I mproperl y seated beari ng
cups and cones are subject to l owmi l eage fai l ure.
(2) Beari ng cups and cones shoul d be repl aced i f
they show si gns of pi tti ng or heat di stress. I f di stress
i s seen on ei ther the cup or beari ng rol l ers, both cup
and cone must be repl aced.
(3) Beari ng prel oad and drag torque speci fi cati ons
must be mai ntai ned to avoi d premature beari ng fai l -
ures. Used (ori gi nal ) beari ngs may l ose up to 50% of
thei r ori gi nal drag torque after break i n. Al l beari ng
adjustments must be made wi th no other component
i nterference or gear i ntermesh.
(4) Repl ace beari ngs as a pai r: I f one di fferenti al
beari ng i s defecti ve, repl ace both di fferenti al bear-
i ngs.
(5) Beari ng cones must not be reused i f removed.
(6) Turni ng torque readi ngs shoul d be obtai ned
whi l e smoothl y rotati ng i n ei ther di recti on.
INTERMEDIATE SHAFT BEARING PRELOAD
The i ntermedi ate shaft prel oad must be checked i f
the housi ng, i ntermedi ate shaft, beari ng pl ate, bear-
i ngs, or transaxl e case are repl aced.
The i ntermedi ate shaft beari ng prel oad procedure
must be done wi th the transaxl e out of the vehi cl e
and on a bench.
(1) Remove end cover (Fi g. 226).
(2) Remove 5th shi ft fork rol l pi n (Fi g. 227).
(3) Use Speci al Tool 6252 to hol d 5th gear. Remove
i nput shaft 5th gear nut (Fi g. 228).
(4) Remove 5th gear synchro snap ri ng (Fi g. 229).
(5) Remove 5th gear synchro, synchro pl ate, and
fork.
(6) Remove 5th dri ve gear off of the i nput shaft
(Fi g. 230).
(7) Remove beari ng retai ner pl ate (Fi g. 231).
(8) Remove beari ng prel oad shi m (Fi g. 232).
(9) Bol t down the beari ng support pl ate i n two
pl aces (veri fy dowel s are i n pl ace).
(10) Seat the i ntermedi ate beari ng cup agai nst the
beari ng.
(11) Measure depth of i ntermedi ate beari ng cup
wi th di al depth gauge (Fi g. 233).
Fig. 224 Crossover Cable Adjustment
Fig. 225 Auxiliary Vent Installation
Fig. 226 End Cover Removed
(12) Add .007 (0.178) to the depth measurement
taken. Thi s amount i s the actual si ze of the beari ng
shi m needed.
(13) Remove the two bol ts retai ni ng the beari ng
support pl ate. Remove the beari ng support pl ate.
Fig. 228 5th Gear Retaining Nut
Fig. 230 5th Gear
Fig. 231 Bearing Retainer Plate
equi val ent onto beari ng support pl ate. I nstal l beari ng
support pl ate.
(15) I nstal l necessary shi m cal cul ated from Step
12
(16) I nstal l beari ng retai ner pl ate. Ti ghten beari ng
retai ner pl ate to 17 Nm (250 i n. l bs.).
(17) I nstal l 5th dri ve gear onto the i nput shaft.
(18) I nstal l 5th gear, synchro, fork, and pl ate.
(19) I nstal l 5th gear synchro snap ri ng.
(20) I nstal l 5th gear shi ft fork rol l pi n.
(21) Use Speci al Tool 6252 to hol d 5th gear and
i nstal l new 5th gear nut at i nput shaft. Ti ghten the
retai ni ng nut to 176 Nm (130 ft. l bs.).
(22) Use Speci al Tool 6930 to stake the 5th gear
retai ni ng nut onto the i nput shaft (Fi g. 234).
equi val ent onto end cover. I nstal l 5th gear/synchro
end cover. Ti ghten bol ts to 28 Nm (250 i n. l bs.).
SPECIFICATIONS
A-598 (T-750) MANUAL TRANSAXLE
DESCRIPTION TORQUE
Back-up Lamp Swi tch. . . . . . . . . .27 Nm (20 ft. l bs.)
Beari ng Retai ner Pl ate. . . . . . . .28 Nm (250 i n. l bs.)
Crossover Cabl e Adj. Screw . . . . . .8 Nm (70 i n. l bs.)
Drai n Pl ug . . . . . . . . . . . . . . . . . .23 Nm (17 ft. l bs.)
Di fferenti al Housi ng . . . . . . . . . . .54 Nm (40 ft. l bs.)
Di ff. Beari ng Retai ner . . . . . . . . .61 Nm (45 ft. l bs.)
Di ff. Ri ng Gear Bol ts . . . . . . . . . .94 Nm (70 ft. l bs.)
End Cover Bol ts . . . . . . . . . . . . . .28 Nm (21 ft. l bs.)
Extensi on Housi ng . . . . . . . . . . .28 Nm (250 i n. l bs.)
Gearshi ft Housi ng . . . . . . . . . . .28 Nm (250 i n. l bs.)
*I nput Gear Nut . . . . . . . . . . . .176 Nm (130 ft. l bs.)
I nput Retai ner . . . . . . . . . . . . . .28 Nm (250 i n. l bs.)
Reverse Bl ocker . . . . . . . . . . . . .12 Nm (105 i n. l bs.)
Transaxl e Case Bol ts . . . . . . . . . .29 Nm (21 ft. l bs.)
Vehi cl e Speed Sensor . . . . . . . . . . .7 Nm (60 i n. l bs.)
Vent . . . . . . . . . . . . . . . . . . . . . . . .6 Nm (60 i n. l bs.)
NOTE: *The 5th/input gear is torqued to specifica-
tion and then staked in two places using Special
Tool 6930.
NOTE: Bolts that have thread sealer or torque lock
patches should not be reused. Always install new
bolts in these applications.
DESCRIPTION TORQUE
Back-up Lamp Swi tch. . . . . . . . . .27 Nm (20 ft. l bs.)
Beari ng Retai ner Pl ate. . . . . . . .28 Nm (250 i n. l bs.)
Crossover Cabl e Adj. Screw . . . . . .8 Nm (70 i n. l bs.)
Drai n Pl ug . . . . . . . . . . . . . . . . . .23 Nm (17 ft. l bs.)
Modul ar Cl utch to Dri ve
Pl ate Bol ts . . . . . . . . . . . . . . . .74 Nm (55 ft. l bs.)
Transaxl e Case Bol ts . . . . . . . . . .29 Nm (21 ft. l bs.)
Vehi cl e Speed Sensor . . . . . . . . . . .7 Nm (60 i n. l bs.)
Vent . . . . . . . . . . . . . . . . . . . . . . . .6 Nm (60 i n. l bs.)
Fig. 233 Measure Depth Of Cup
Fig. 234 Staking 5th Gear Retaining Nut
NV T750 (A-598) MANUAL TRANSAXLE FLUID
FILL
TRANSAXLE
METRIC MEA-
SURE
U.S. MEASURE
NV T750 1.9-2.2 Liters 2.0-2.3 Quarts
SPECIAL TOOLS
A-598 (T-750) MANUAL TRANSAXLE
A-558 MANUAL TRANSAXLE FLUID FILL
The fl ui d l evel shoul d be wi thi n 3.175mm (1/8 i nch)
from the bottom of the transaxl e fi l l hol e (vehi cl e must
be l evel when checki ng).
Fi l l transaxl e toproper l evel wi th SAE 5W-30 engi ne oi l ,
meeti ng SG and/or SG-CD qual i fi cati ons. G5 SAE
10W-40 engi ne oi l i s a sui tabl e servi ce fi l l al ternati ve.
TRANSAXLE
METRIC MEA-
SURE
U.S. MEASURE
A-558 1.9-2.2 Liters 2.0-2.3 Quarts
Bearing Splitter 1130
Slide Hammer 3752
Bearing Remover 5066
Gear Holder 6252
Staking Tool 6930
Bearing Installer 6933
Puller Press C-293-PA
Adapters C-293-45
Handle C-4171
Adapter C-4996
Bearing Remover L-4518
Bearing Installer MD998323
Bearing Remover MD99880201
Fig. 235 Handle C-4171
Fig. 236 Bearing Installer L-4520
TIRES AND WHEELS
CONTENTS
page page
TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
TIRES
INDEX
page page
RADIAL-PLY TIRES . . . . . . . . . . . . . . . . . . . . . . . 2
REPLACEMENT TIRES . . . . . . . . . . . . . . . . . . . . 3
SPARE TIRE (TEMPORARY) . . . . . . . . . . . . . . . . 2
TIRE INFLATION PRESSURES . . . . . . . . . . . . . . 2
TIRE INFORMATION . . . . . . . . . . . . . . . . . . . . . . 1
TIRE PRESSURE FOR HIGH-SPEED DRIVING . . 3
LEAD CORRECTION CHART . . . . . . . . . . . . . . . . 4
PRESSURE GAUGES . . . . . . . . . . . . . . . . . . . . . 3
TIRE NOISE OR VIBRATION . . . . . . . . . . . . . . . . 4
TIRE WEAR PATTERNS . . . . . . . . . . . . . . . . . . . . 4
TREAD WEAR INDICATORS . . . . . . . . . . . . . . . . 3
SERVICE PROCEDURES
REPAIRING TIRE LEAKS . . . . . . . . . . . . . . . . . . . 6
TIRE AND WHEEL MATCH MOUNTING . . . . . . . . 6
TIRE AND WHEEL ROTATION (NON-
DIRECTIONAL THREAD PATTERN) . . . . . . . . . . 6
CLEANING TIRES . . . . . . . . . . . . . . . . . . . . . . . . 7
SPECIFICATIONS
TIRE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . 8
TIRE INFORMATION
Ti res are desi gned and engi neered for each speci fi c
vehi cl e. They provi de the best overal l performance
for normal operati on. The ri de and handl i ng charac-
teri sti cs match the vehi cl es requi rements. Wi th
proper care they wi l l gi ve excel l ent rel i abi l i ty, trac-
ti on, ski d resi stance, and tread l i fe.
Dri vi ng habi ts have more effect on ti re l i fe than
any other factor. Careful dri vers wi l l obtai n, i n most
cases, much greater mi l eage than severe use or care-
l ess dri vers. A few of the dri vi ng habi ts whi ch wi l l
shorten the l i fe of any ti re are:
Rapi d accel erati on
Severe appl i cati on of brakes
Hi gh-speed dri vi ng
Taki ng turns at excessi ve speeds
Stri ki ng curbs and other obstacl es
Radi al pl y ti res are more prone to i rregul ar tread
wear. I t i s i mportant to fol l ow the ti re rotati on i nter-
val shown i n the secti on on Ti re Rotati on. Thi s wi l l
hel p to achi eve a greater tread-l i fe potenti al .
TIRE IDENTIFICATION
Ti re type, si ze, aspect rati o and speed rati ng are
encoded i n the l etters and numbers i mpri nted on the
si de wal l of the ti re. Refer to the chart to deci pher
the ti re i denti fi cati on code (Fi g. 1).
Performance ti res wi l l have a speed rati ng l etter
after the aspect rati o number. The speed rati ng i s not
al ways pri nted on the ti re si dewal l . The l etter S i ndi -
cates that the ti re i s speed rated up to 112 mph.
Q up to 100 mph
T up to 118 mph
U up to 124 mph
H up to 130 mph
V up to 149 mph
Z more than 149 mph (consul t the ti re manu-
facturer for the speci fi c speed rati ng)
An Al l Season type ti re wi l l have ei ther M +S, M
& S or MS (i ndi cati ng mud and snow tracti on)
i mpri nted on the si de wal l .
TIRE CHAINS
Thi s vehi cl e was desi gned to al l ow the use of a
speci fi ed type of snow chai n on the ti res. Onl y com-
pact snow chai ns or other tracti on ai dsmeeti ng SAE
type Cl ass S speci fi cati ons may be used. Any style
NS TIRES AND WHEELS 22 - 1
snow chain or other type of traction aid is not
to be used on the compact spare tire.
RADIAL-PLY TIRES
Radi al -pl y ti res i mprove handl i ng, tread l i fe, ri de
qual i ty and decrease rol l i ng resi stance.
Radi al -pl y ti res must al ways be used i n sets of four
and under no ci rcumstances shoul d they be used on
the front onl y. They may be mi xed wi th a temporary
spare ti re when necessary. A maxi mum speed of 50
MPH i s recommended whi l e a temporary spare i s i n
use.
Radi al -pl y ti res have the same l oad-carryi ng capac-
i ty as other types of ti res of the same si ze. They al so
use the same recommended i nfl ati on pressures.
The use of oversi zed ti res, ei ther i n the front or
rear of the vehi cl e, can cause vehi cl e dri ve trai n fai l -
ure. Thi s coul d al so cause i naccurate wheel speed
si gnal s when the vehi cl e i s equi pped wi th Anti -Lock
Brakes.
I t i s recommended that ti res from di fferent manu-
factures NOT be mi xed. The proper ti re pressure
shoul d be mai ntai ned on al l four ti res. For proper
ti re pressure refer to the Ti re I nfl ati on Pressure
Pl acard l ocated i n the gl ove box.
SPARE TIRE (TEMPORARY)
The temporary spare ti re i s desi gned for emer-
gency use onl y. The ori gi nal ti re shoul d be repai red
and rei nstal l ed at the fi rst opportuni ty, or repl aced
wi th a new. Do not exceed speeds of 50 MPH when
the temporary spare ti re i s i n use on the vehi cl e.
Refer to the Owners Manual for compl ete detai l s.
TIRE INFLATION PRESSURES
WARNING: OVER OR UNDER INFLATED TIRES
CAN AFFECT VEHICLE HANDLING. THE TIRE CAN
FAIL SUDDENLY, RESULTING IN LOSS OF VEHICLE
CONTROL.
Under i nfl ati on causes rapi d shoul der wear of the
ti re tread and ti re fl exi ng. Thi s can resul t i n fai l ure
of the ti re. (Fi g. 2).
Over i nfl ati on causes rapi d center wear and l oss of
the ti res abi l i ty tocushi on shocks (Fi g. 3).
Fig. 1 Tire Size Identification
Fig. 2 Under Inflation Wear
Fig. 3 Over Inflation Wear
22 - 2 TIRES AND WHEELS NS
I mproper i nfl ati on can cause:
Uneven wear patterns
Reduced tread l i fe
Reduced fuel economy
Unsati sfactory ri de
The vehi cl e to dri ft.
Proper ti re ai r i nfl ati on pressure speci fi cati ons can
be found on the Vehi cl e Ti re Pl acard provi ded wi th
the vehi cl e. See owners manual .
Ti re pressures have been chosen to provi de safe
operati on, vehi cl e stabi l i ty, and a smooth ri de. Ti re
pressure shoul d be checked col d once per month.
Check ti re pressure more frequentl y when the
weather temperature vari es wi del y. Ti re pressure wi l l
decrease when the outdoor temperature drops.
Ti re i nfl ati on pressures speci fi ed on the pl acard
are al ways col d i nfl ati on pressure. Col d i nfl ati on
pressure i s obtai ned after the vehi cl e has not been
operated for at l east 3 hours, or the vehi cl e i s dri ven
l ess than one mi l e after bei ng i noperati ve for 3
hours. Ti re i nfl ati on pressures may i ncrease from 2
to 6 pounds per square i nch (psi ) duri ng operati on.
Do not reduce thi s normal pressure bui l d-up.
TIRE PRESSURE FOR HIGH-SPEED DRIVING
Chrysl er Corporati on advocates dri vi ng at safe
speeds wi thi n posted speed l i mi ts. Where speed l i m-
i ts al l ow the vehi cl e to be dri ven at hi gh speeds, cor-
rect ti re i nfl ati on pressure i s very i mportant. For
speeds up to and i ncl udi ng 75 mph (120 km/h), ti res
must be i nfl ated to the pressures shown on the ti re
pl acard.
Vehi cl es l oaded to the maxi mum capaci ty shoul d
not be dri ven at speeds above 75 mph (120 km/h).
For emergency vehi cl es that are dri ven at speeds
over 90 mph (144 km/h), speci al hi gh-speed ti res
must be used. Consul t ti re manufacturer for correct
i nfl ati on pressure recommendati ons.
REPLACEMENT TIRES
The ori gi nal equi pment ti res provi de a proper bal -
ance of many characteri sti cs such as:
Ri de
Noi se
Handl i ng
Durabi l i ty
Tread l i fe
Tracti on
Rol l i ng resi stance
Speed capabi l i ty
I t i s recommend that ti res equi val ent to the ori gi -
nal equi pment ti res be used when repl acement i s
needed.
Fai l ure to use equi val ent repl acement ti res may
adversel y affect the safety and handl i ng of the vehi cl e.
The use of oversi ze ti res not l i sted i n the speci fi ca-
ti on charts may cause i nterference wi th vehi cl e com-
ponents. Under extremes of suspensi on and steeri ng
travel , i nterference wi th vehi cl e components may
cause ti re damage.
WARNING: FAILURE TO EQUIP THE VEHICLE WITH
TIRES HAVING ADEQUATE SPEED CAPABILITY
CAN RESULT IN SUDDEN TIRE FAILURE.
PRESSURE GAUGES
A qual i ty ai r pressure gauge i s recommended to
check ti re pressure. After checki ng the ai r pressure,
repl ace val ve cap fi nger ti ght.
TREAD WEAR INDICATORS
Tread wear i ndi cators are mol ded i nto the bottom
of the tread grooves. When tread depth i s 1.6 mm
(1/16 i n.), the tread wear i ndi cators wi l l appear as a
13 mm (1/2 i n.) band (Fi g. 4).
Ti re repl acement i s necessary when i ndi cators
appear i n two or more grooves or i f l ocal i zed bal di ng
occurs.
Fig. 4 Tread Wear Indicators
TIRE WEAR PATTERNS
Under i nfl ati on wi l l cause wear on the shoul ders of
ti re. Over i nfl ati on wi l l cause wear at the center of
ti re.
Excessi ve camber causes the ti re to run at an
angl e to the road. One si de of tread i s then worn
more than the other (Fi g. 5).
Excessi ve toe-i n or toe-out causes wear on the
tread edges and a feathered effect across the tread
(Fi g. 5).
TIRE NOISE OR VIBRATION
Radi al -pl y ti res are sensi ti ve to force i mpul ses
caused by i mproper mounti ng, vi brati on, wheel
defects, or possi bl y ti re i mbal ance.
To fi nd out i f ti res are causi ng the noi se or vi bra-
ti on, dri ve the vehi cl e over a smooth road at varyi ng
speeds. Note the noi se l evel duri ng accel erati on and
decel erati on. The engi ne, di fferenti al and exhaust
noi ses wi l l change as speed vari es, whi l e the ti re
noi se wi l l usual l y remai n constant.
LEAD CORRECTION CHART
Use the fol l owi ng chart to correct a vehi cl e l eadi ng
or dri fti ng probl em.
Fig. 5 Tire Wear Patterns
LEAD CORRECTION CHART
SERVICE PROCEDURES
TIRE AND WHEEL ROTATION (NON-DIRECTIONAL
THREAD PATTERN)
Ti res on the front and rear axl es operate at di ffer-
ent l oads and perform di fferent functi ons. For these
reasons, they wear at unequal rates, and tend to
devel op i rregul ar wear patterns. These effects can be
reduced by ti mel y rotati on of ti res. The benefi ts of
rotati on are especi al l y worthwhi l e. Rotati on wi l l
i ncrease tread l i fe, hel p to mai ntai n mud, snow, and
wet tracti on l evel s, and contri bute to a smooth, qui et
ri de.
The suggested rotati on method i s the forward-cross
ti re rotati on method (Fi g. 6). Thi s method takes
advantage of current ti re i ndustry practi ce whi ch
al l ows rotati on of radi al -pl y ti res. Other rotati on
methods may be used, but may not have al l the ben-
efi ts of the recommended method.
NOTE: Only the 4 tire rotation method may be used
if the vehicle is equipped with a low mileage or tem-
porary spare tire.
REPAIRING TIRE LEAKS
For proper repai ri ng, a radi al ti re must be removed
from the wheel . Before di smounti ng the ti re from the
wheel , a reference mark shoul d be pl aced on the ti re
at the val ve stem l ocati on. Thi s reference mark wi l l
ensure that the ti re i s remounted back on the wheel
i n i ts ori gi nal posi ti on. Repai rs shoul d onl y be made
i f the defect, or puncture, i s i n the tread area (Fi g.
7). The ti re shoul d be repl aced i f the puncture i s
l ocated i n the si dewal l .
Defl ate ti re compl etel y before di smounti ng ti re
from the wheel . Use l ubri cati on such as a mi l d soap
sol uti on when di smounti ng or mounti ng ti re. Use
tool s free of burrs or sharp edges whi ch coul d dam-
age the ti re or wheel ri m.
Before mounti ng ti re on wheel , make sure al l rust
i s removed from the ri m bead and repai nt i f neces-
sary.
I nstal l wheel on vehi cl e, and progressi vel y ti ghten
al l 5 wheel nuts to a torque of 135 Nm (100 ft. l bs.).
TIRE AND WHEEL MATCH MOUNTING
Wheel s and ti res are match mounted at the factory.
Thi s means that the hi gh spot of the ti re i s matched
to the l ow spot on the wheel ri m. Thi s techni que i s
used to reduce run-out i n the wheel /ti re assembl y.
The hi gh spot on the ti re i s marked wi th a pai nt
mark or a bri ght col ored adhesi ve l abel on the out-
board si dewal l . The l ow spot on the ri m i s i denti fi ed
wi th a l abel on the outsi de of the ri m and a dot or
l i ne on the i nsi de of the ri m. I f the outsi de l abel has
been removed the ti re wi l l have to be removed to
l ocate the dot or l i ne on the i nsi de of the ri m.
Before di smounti ng a ti re from i ts wheel , a refer-
ence mark shoul d be pl aced on the ti re at the val ve
stem l ocati on. Thi s reference wi l l ensure that i t i s
remounted i n the ori gi nal posi ti on on the wheel .
(1) Measure the total i ndi cator runout on the cen-
ter of the ti re tread ri b. Record the i ndi cator readi ng.
Mark the ti re to i ndi cate the hi gh spot. Pl ace a mark
on the ti re at the val ve stem l ocati on (Fi g. 8).
(2) Break down the ti re and remount i t 180
degrees on the ri m (Fi g. 9).
(3) Measure the total i ndi cator runout agai n. Mark
the ti re to i ndi cate the hi gh spot.
Fig. 6 Forward-Cross Tire Rotation Method
Fig. 7 Tire Repair Area
(4) I f runout i s sti l l excessi ve, the fol l owi ng proce-
dures must be done.
I f the hi gh spot i s wi thi n 102 mm (4.0 i n.) of the
fi rst spot and i s sti l l excessi ve, repl ace the ti re.
I f the hi gh spot i s wi thi n 102 mm (4.0 i n.) of the
fi rst spot on the wheel , the wheel may be out of spec-
i fi cati ons. Refer to Wheel and Ti re Runout.
I f the hi gh spot i s NOT wi thi n 102 mm (4.0 i n.)
of ei ther hi gh spot, draw an arrow on the tread from
second hi gh spot to fi rst. Break down the ti re and
remount i t 90 degrees on ri m i n that di recti on (Fi g.
10). Thi s procedure wi l l normal l y reduce the runout
to an acceptabl e amount.
CLEANING TIRES
Remove protecti ve coati ng on ti res before del i very
of vehi cl e. Thi s coati ng may cause deteri orati on of
ti res.
To remove the protecti ve coati ng appl yi ng warm
water and l et i t soak for a few mi nutes. Then scrub
the coati ng away wi th a soft bri stl e brush. Steam
cl eani ng may al so be used to remove the coati ng.
NOTE: DO NOT use gasoline, mineral oil, oil-based
solvent or wire brush for cleaning.
Fig. 8 First Measurement On Tire
Fig. 9 Remount Tire 180 Degrees
Fig. 10 Remount Tire 90 Degrees In Direction of
Arrow
SPECIFICATIONS
TIRE SPECIFICATIONS
WHEELS
INDEX
page page
WHEEL INFORMATION . . . . . . . . . . . . . . . . . . . . 9
TIRE AND WHEEL RUNOUT . . . . . . . . . . . . . . . 10
WHEEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . 9
SERVICE PROCEDURES
TIRE AND WHEEL BALANCE . . . . . . . . . . . . . . . 11
WHEEL INSTALLATION . . . . . . . . . . . . . . . . . . . 11
SPECIFICATIONS
WHEEL SPECIFICATIONS . . . . . . . . . . . . . . . . . 12
WHEEL INFORMATION
Ori gi nal equi pment wheel s are desi gned for proper
operati on at al l l oads up to the speci fi ed maxi mum
vehi cl e capaci ty.
Al l model s use steel or al umi num drop center
wheel s. Every wheel has rai sed secti ons between the
ri m fl anges and ri m drop wel l cal l ed safety humps
(Fi g. 1).
I ni ti al i nfl ati on of the ti res forces the bead over
these rai sed secti ons. I n case of ai r l oss the rai sed
secti ons hol d the ti re i n posi ti on on the wheel unti l
the vehi cl e can be brought to a safe stop.
Cast al umi num wheel s requi re speci al bal ance
wei ghts to fi t on the thi cker fl ange of the ri m and
speci al wheel cl amps for the al i gnment equi pment.
The wheel studs and nuts are desi gned for the spe-
ci fi c wheel appl i cati ons used on a vehi cl e and must
be repl aced wi th equi val ent parts.
Do not use repl acement parts of l esser qual i ty or of
a substi tute desi gn from the ori gi nal equi pment part.
Al l al umi num wheel s have wheel stud nuts wi th
an enl arged nose. Thi s enl arged nose i s necessary to
ensure proper retenti on of the wheel s.
Vehi cl es that are equi pped wi th bol t-on wheel cov-
ers use l arge nose wheel nuts. The wheel nuts used
on a vehi cl e equi pped wi th bol t-on wheel covers are
external l y threaded so that the wheel covers can be
attached to the wheel nuts.
Before i nstal l i ng a wheel , remove any bui l dup of
corrosi on on the wheel mounti ng surface.
WARNING: INSTALLING WHEELS WITHOUT GOOD
METAL-TO-METAL CONTACT COULD CAUSE LOOS-
ENING OF WHEEL LUG NUTS. THIS COULD
ADVERSELY AFFECT THE SAFETY AND HANDLING
OF YOUR VEHICLE.
WHEEL INSPECTION
Wheel s must be repl aced i f they:
Have excessi ve run out
Are bent or dented
Leak ai r
Have damaged wheel l ug hol es
Wheel repai rs empl oyi ng hammeri ng, heati ng,
wel di ng or repai ri ng l eaks are not al l owed.
Ori gi nal equi pment repl acement wheel s are avai l -
abl e through the deal er. When obtai ni ng repl acement
wheel s from any other source, they must be equi va-
l ent i n l oad carryi ng capaci ty. The wheel features
(di ameter, wi dth, offset, brake cl earance, and mount-
i ng confi gurati on) must match the ori gi nal equi p-
ment wheel s.
WARNING: FAILURE TO USE ORIGINAL EQUIP-
MENT REPLACEMENT WHEELS MAY ADVERSELY
AFFECT THE SAFETY AND HANDLING OF YOUR
VEHICLE.
Fig. 1 Safety Rim
WARNING: REPLACEMENT WITH USED WHEELS
IS NOT RECOMMENDED. THE SERVICE HISTORY
OF THE RIM MAY HAVE INCLUDED SEVERE TREAT-
MENT OR VERY HIGH MILEAGE. THE RIM COULD
FAIL WITHOUT WARNING.
TIRE AND WHEEL RUNOUT
NOTE: Runout should always be measured off the
vehicle and on a suitable balance machine.
Radi al run out i s the di fference between the hi gh
and l ow poi nts on the outer edge of the ti re or wheel .
Lateral run out i s the total si detosi de wobbl e of
the ti re or wheel .
Radi al run out of more than 0.762 mm (.030 i nch)
measured at the center l i ne of the tread may cause
the vehi cl e to shake.
Lateral run out of more than 0.762 mm (.030 i nch)
measured at the si de of the ti re as cl ose to the tread
as possi bl e may cause the vehi cl e to shake.
Someti mes radi al run out can be reduced by rel o-
cati ng the wheel and ti re on the wheel studs (See
Method 1). I f thi s does not reduce run out to an
acceptabl e l evel , the ti re can be rotated on the wheel .
(See Method 2).
METHOD 1 (RELOCATE WHEEL ON HUB)
Check accuracy of the wheel mounti ng surface;
adjust wheel beari ngs.
Dri ve vehi cl e a short di stance to el i mi nate ti re fl at
spotti ng from a parked posi ti on.
Veri fy al l wheel nuts are properl y torqued (Fi g. 2).
Use run out gauge D-128-TR to determi ne run out
(Fi g. 3).
Rel ocate the wheel on the mounti ng studs, two
studs over from the ori gi nal posi ti on.
Reti ghten wheel nuts unti l al l are properl y
torqued. Thi s wi l l prevent brake di storti on.
Check radi al run out. I f sti l l excessi ve, mark ti re
si dewal l , wheel , and stud at poi nt of maxi mum run
out (Fi g. 4) and proceed to Method 2.
METHOD 2 (RELOCATE TIRE ON WHEEL)
Rotati ng ti re on wheel i s parti cul arl y effecti ve
when there i s run out i n both ti re and wheel .
Remove ti re from wheel and remount wheel on hub
i n former posi ti on.
Check the radi al run out of the wheel (Fi g. 5). The
radi al run out shoul d be no more than 0.5 mm (0.020
i nch) for steel wheel s and 0.38 mm (0.015 i nch) for
cast al umi num wheel s.
Check the l ateral run out of the wheel (Fi g. 6). The
l ateral runout shoul d be no more than 0.8 mm (0.032
i nch).
I f the poi nt of greatest wheel radi al run out i s near
the ori gi nal chal k mark, remount the ti re on the ri m
180 degrees from i ts ori gi nal posi ti on. Recheck the
run out. I f thi s does not reduce the run out to an
acceptabl e l evel , repl ace the wheel and/or the ti re.
Fig. 2 Tightening Wheel Nuts
Fig. 3 Run Out Gauge
Fig. 4 Chalk Marking On Wheel, Tire And Stud
SERVICE PROCEDURES
WHEEL INSTALLATION
To i nstal l the wheel , fi rst posi ti on i t properl y on
the mounti ng surface of the hub usi ng the hub pi l ot
as a gui de. Al l wheel nuts shoul d be l i ghtl y ti ghtened
before progressi vel y ti ghteni ng them i n the proper
sequence (Fi g. 7). Then ful l y ti ghten the wheel nuts
i n the proper sequence (Fi g. 7) to a torque of 135
Nm (100 ft. l bs.). Never use oi l or grease on studs or
nuts.
TIRE AND WHEEL BALANCE
Bal anci ng need i s i ndi cated by vi brati on of seats,
fl oor pan, or steeri ng wheel . The vi brati on wi l l be
noti ced mostl y when dri vi ng over 90 km/h (55 mph)
on a smooth road.
I t i s recommended that a two pl ane dynami c bal -
ancer be used when a wheel and ti re assembl y
requi re bal anci ng. Stati c bal anci ng shoul d be used
onl y when a two pl ane bal ancer i s not avai l abl e.
Off-vehi cl e ti re and wheel bal anci ng i s recom-
mended to be used on thi s vehi cl e.
NOTE: If on vehicle equipment is being used to bal-
ance the tire /wheel assemblies, remove the oppo-
site tire/wheel from the vehicle.
For stati c bal anci ng, fi nd the l ocati on of heavy spot
on ti re/wheel causi ng the i mbal ance. Counter bal ance
wheel di rectl y opposi te the heavy spot. Determi ne
wei ght requi red to counterbal ance the area of i mbal -
ance. Pl ace hal f of thi s wei ght on the inner ri m
fl ange and the other hal f on the outer ri m fl ange
(Fi g. 8).
For dynami c bal anci ng, the bal anci ng equi pment i s
desi gned to i ndi cate the l ocati on and amount of
wei ght to be appl i ed to both the i nner and outer ri m
fl anges (Fi g. 9).
Fig. 5 Checking Wheel Radial Run Out
Fig. 6 Checking Wheel Lateral Run Out
Fig. 7 Tightening Wheel Nuts
SPECIFICATIONS
WHEEL SPECIFICATIONS
Wheel:
Mounti ng Stud Si ze. . . . . . . . . . . . . .M12 x 1.5mm
Mounti ng Stud Lug Nut Hex Si ze . . . . . . . . .19mm
Mounti ng Lug Nut Ti ghteni ng
Torque . . . . . . . . . . . . . . . .135 Nm (100 ft. l bs.)
Fig. 8 Static Unbalance & Balance
Fig. 9 Dynamic Unbalance & Balance
BODY
CONTENTS
page page
BODY COMPONENT SERVICE . . . . . . . . . . . . . . 22
GENERAL SERVICE INFORMATION . . . . . . . . . . . 1
PAINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
STATIONARY GLASS . . . . . . . . . . . . . . . . . . . . . . . 4
GENERAL SERVICE INFORMATION
INDEX
page
GENERAL INFORMATION
SAFETY PRECAUTIONS AND WARNINGS . . . . . . 1
GENERAL INFORMATION
USE A OSHA APPROVED BREATHING FILTER
WHEN SPRAYING PAINT OR SOLVENTS IN A CON-
FINED AREA. PERSONAL INJURY CAN RESULT.
AVOID PROLONGED SKIN CONTACT WITH
PETROLEUM OR ALCOHOL BASED CLEANING
SOLVENTS. PERSONAL INJURY CAN RESULT.
DO NOT STAND UNDER A HOISTED VEHICLE
THAT IS NOT PROPERLY SUPPORTED ON SAFETY
STANDS. PERSONAL INJURY CAN RESULT.
CAUTION: When holes must be drilled or punched
in an inner body panel, verify depth of space to the
outer body panel, electrical wiring, or other compo-
nents. Damage to vehicle can result.
Do not weld exterior panels unless combustible
material on the interior of vehicle is removed from
the repair area. Fire or hazardous conditions, can
result.
Always have a fire extinguisher ready for use
when welding.
Disconnect the negative (-) cable clamp from the
battery when servicing electrical components that
are live when the ignition is OFF. Damage to electri-
cal system can result.
Do not use abrasive chemicals or compounds on
painted surfaces. Damage to finish can result.
Do not use harsh alkaline based cleaning sol-
vents on painted or upholstered surfaces. Damage
to finish or color can result.
Do not hammer or pound on plastic trim panel
when servicing interior trim. Plastic panels can
break.
Chrysl er Corporati on uses many di fferent types of
push-i n fasteners to secure the i nteri or and exteri or
tri m to the body. Most of these fasteners can be
reused to assembl e the tri m duri ng vari ous repai r
procedures. At ti mes, a push-i n fastener cannot be
removed wi thout damagi ng the fastener or the com-
ponent i t i s hol di ng. I f i t i s not possi bl e to remove a
fastener wi thout damagi ng a component or body, cut
or break the fastener and use a new one when
i nstal l i ng the component. Never pry or pound on a
pl asti c or pressed-board tri m component. Usi ng a
sui tabl e fork-type pryi ng devi ce, pry the fastener
from the retai ni ng hol e behi nd the component bei ng
removed. When i nstal l i ng, veri fy fastener al i gnment
wi th the retai ni ng hol e by hand. Push di rectl y on or
over the fastener unti l i t seats. Appl y a l ow-force pul l
to the panel to veri fy that i t i s secure.
fasteners or captured edges hol di ng the component i n
pl ace.
NS BODY 23 - 1
PAINT
INDEX
page page
GENERAL INFORMATION
AFTERMARKET PAINT REPAIR PRODUCTS . . . . 3
BASE COAT/CLEAR COAT FINISH . . . . . . . . . . . . 2
PAINT CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
PAINTED SURFACE TOUCH-UP . . . . . . . . . . . . . 2
WET SANDING, BUFFING, AND POLISHING . . . . 2
GENERAL INFORMATION
PAINT CODE
A pai nt code i s provi ded on the body code pl ate
l ocated i n the engi ne compartment. Refer to the
I ntroducti on secti on at the front of thi s manual for
body code pl ate descri pti on. The pai nt and tri m codes
are al so i ncl uded on the Vehi cl e Safety Label l ocated
on the dri vers door end frame.
BASE COAT/CLEAR COAT FINISH
On most vehi cl es a two-part pai nt appl i cati on (base
coat/cl ear coat) i s used. Col or pai nt that i s appl i ed to
pri mer i s cal l ed base coat. The cl ear coat protects the
base coat from ul travi ol et l i ght and provi des a dura-
bl e hi gh-gl oss fi ni sh.
WET SANDING, BUFFING, AND POLISHING
Mi nor aci d etchi ng, orange peel , or smudgi ng i n
cl ear coat or si ngl e-stage fi ni shes can be reduced
wi th l i ght wet sandi ng, hand buffi ng, and pol i shi ng.
If the finish has been wet sanded in the past, it
cannot be repeated. Wet sanding operation
should be performed by a trained automotive
paint technician.
CAUTION: Do not remove clear coat finish, if
equipped. Base coat paint must retain clear coat for
durability.
PAINTED SURFACE TOUCH-UP
When a pai nted metal surface has been scratched
or chi pped, i t shoul d be touched-up as soon as possi -
bl e to avoi d corrosi on. For best resul ts, use Mopar
Scratch Fi l l er/Pri mer, Touch-Up Pai nts and Cl ear Top
Coat. Refer to I ntroducti on group of thi s manual for
Body Code Pl ate i nformati on.
TOUCH-UP PROCEDURE
(1) Scrape l oose pai nt and corrosi on from i nsi de
scratch or chi p.
(2) Cl ean affected area wi th Mopar Tar/Road Oi l
Remover, and al l ow to dry.
(3) Fi l l the i nsi de of the scratch or chi p wi th a coat
of fi l l er/pri mer. Do not overl ap pri mer onto good sur-
face fi ni sh. The appl i cator brush shoul d be wet
enough to puddl e-fi l l the defect wi thout runni ng. Do
not stroke brush appl i cator on body surface. Al l ow
the fi l l er/pri mer to dry hard.
(4) Cover the fi l l er/pri mer wi th col or touch-up
pai nt. Do not overl ap touch-up col or onto the ori gi nal
col or coat around the scratch or chi p. Butt the new
col or to the ori gi nal col or, i f possi bl e. Do not stroke
appl i cator brush on body surface. Al l ow touch-up
pai nt to dry hard.
(5) On vehi cl es wi thout cl ear coat, the touch-up
col or can be l i ghtl y wet sanded (1500 gri t) and pol -
i shed wi th rubbi ng compound.
(6) On vehi cl es wi th cl ear coat, appl y cl ear top coat
to touch-up pai nt wi th the same techni que as
descri bed i n Step 4. Al l ow cl ear top coat to dry hard.
I f desi red, Step 5 can be performed on cl ear top coat.
23 - 2 BODY NS
AFTERMARKET PAINT REPAIR PRODUCTS
EXTERIOR COLORS
EXTERIOR
COLOR
CHRY
CODE*
PPG BASF DuPONT S-W ACME
M-S
AKZO NOBEL
SIKKENS
Alpine Green
Pearl coat
VGT 5358 28061 B9843 54162 CHA98VGT
Bright White
Clear Coat
GW7 4037 18238 B8833 37298 CHA88GW7
Candy Apple
Red Mt. Tint
Clear Coat
RH2 4974
5025
26098 B9616 51063
5106
CHA95RH2
Deep Amethyst
Pearl Coat
TCN 5246 27038 B9736 52566 CHA97TCN
Deep
CranberryPearl
Coat
VMT 5359 28071 B9842 54119 CHA98VMT
Deep Hunter
Green Pearl
Coat
SG8 47439 26078 B9609 5106 CHA95SG8
Deep Slate
Pearl Coat
VAW 5292 27166 B9774 54118 CHA97VAW
Flame Red
Clear Coat
PR4 4679 21836 B9326 46916 CHA93PR4
Golden White
Pearl Tri-Coat
GW7 83554
83642
26095 B9623
B9624
51074
51075
CHA96SWP
Island Teal
Satin Glow
SPJ 47425 26085 B9610 51065 CHA95SPJ
Light Iris Pearl
Coat
PC5 4788 24078 B9455 48782 CHA94PC5
Light Silverfern
Pearl Coat
RJM 47383 25043 B9525 50269 CHA95RJM
Taupe Frost
Pearl Coat
TTK 5244 27040 B9750 52567 CHA97TTK
*Herberts Standox and Spi es Hecker use the Chrysl er pai nt code as l i sted on the Body Code Pl ate.
INTERIOR COLORS
INTERIOR
COLOR
CHRY
CODE
PPG BASF DuPONT
S-W ACME
M-S
AKZO NOBEL
SIKKENS
Camel K5 27731/2-
1584
26120 C9603 51541 CHARJ5I
Mist Gray C3 35799/2-
1576
25065 C9507 50508 CHARC3I
Silver Fern JK 35798/2-
1577
25066 C9509 50510 CHARJKI
NS BODY 23 - 3
STATIONARY GLASS
INDEX
page page
SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . 4
BODY SIDE/SLIDING DOOR STATIONARY
GLASS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
REAR WINDOW . . . . . . . . . . . . . . . . . . . . . . . . . . 7
WINDSHIELD . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SAFETY PRECAUTIONS
WARNING: DO NOT OPERATE THE VEHICLE
WITHIN 24 HOURS OF WINDSHIELD INSTALLATION.
IT TAKES AT LEAST 24 HOURS FOR URETHANE
ADHESIVE TO CURE. IF IT IS NOT CURED, THE
WINDSHIELD MAY NOT PERFORM PROPERLY IN
AN ACCIDENT.
URETHANE ADHESIVES ARE APPLIED AS A SYS-
TEM. USE GLASS CLEANER, GLASS PREP SOL-
VENT, GLASS PRIMER, PVC (VINYL) PRIMER AND
PINCHWELD (FENCE) PRIMER PROVIDED BY THE
ADHESIVE MANUFACTURER. IF NOT, STRUCTURAL
INTEGRITY COULD BE COMPROMISED.
CHRYSLER DOES NOT RECOMMEND GLASS
ADHESIVE BY BRAND. TECHNICIANS SHOULD
REVIEW PRODUCT LABELS AND TECHNICAL DATA
SHEETS, AND USE ONLY ADHESIVES THAT THEIR
MANUFACTURES WARRANT WILL RESTORE A
VEHICLE TO THE REQUIREMENTS OF FMVSS 212.
TECHNICIANS SHOULD ALSO INSURE THAT PRIM-
ERS AND CLEANERS ARE COMPATIBLE WITH THE
PARTICULAR ADHESIVE USED.
BE SURE TO REFER TO THE URETHANE MANU-
FACTURERS DIRECTIONS FOR CURING TIME
SPECIFICATIONS, AND DO NOT USE ADHESIVE
AFTER ITS EXPIRATION DATE.
VAPORS THAT ARE EMITTED FROM THE URE-
THANE ADHESIVE OR PRIMER COULD CAUSE
PERSONAL INJURY. USE THEM IN A WELL-VENTI-
LATED AREA.
SKIN CONTACT WITH URETHANE ADHESIVE
SHOULD BE AVOIDED. PERSONAL INJURY MAY
RESULT.
ALWAYS WEAR EYE AND HAND PROTECTION
WHEN WORKING WITH GLASS.
CAUTION: Protect all painted and trimmed surfaces
from coming in contact with urethane or primers.
Be careful not to damage painted surfaces when
removing moldings or cutting urethane around
windshield.
I t i s di ffi cul t to sal vage a wi ndshi el d duri ng the
removal operati on. The wi ndshi el d i s part of the
structural support for the roof. The urethane bondi ng
used to secure the wi ndshi el d to the fence i s di ffi cul t
to cut or cl ean from any surface. I f the mol di ngs are
set i n urethane, i t woul d al so be unl i kel y they coul d
be sal vaged. Before removi ng the wi ndshi el d, check
the avai l abi l i ty of the wi ndshi el d and mol di ngs from
the parts suppl i er.
WINDSHIELD
The urethane adhesi ve hol di ng the wi ndshi el d to
the openi ng pi nch wel d (fence) can be cut usi ng a
sharp col d kni fe from the exteri or of the vehi cl e.
Usi ng the col d kni fe method i s effecti ve i f the wi nd-
shi el d i s al ready broken. I f the gl ass must be sal -
vaged, cutti ng the urethane adhesi ve from the
i nteri or of the vehi cl e usi ng a reci procati ng or osci l -
l ati ng power kni fe i s recommended.
WINDSHIELD REMOVAL EXTERIOR METHOD
(1) Remove i nsi de rear vi ew mi rror.
(2) Remove wi ndshi el d wi per arms.
(3) Remove cowl cover.
(4) Remove A-pi l l ar tri m panel s.
(5) Di sconnect wi re connectors to wi ndshi el d
defroster gri d.
(6) Pl ace protecti ve covers over i nstrument panel
and hood.
(7) Remove wi ndshi el d mol di ng (Fi g. 1). Usi ng pl i -
ers, pul l outward on mol di ng at the bottom of A-pi l -
l ars.
(8) Usi ng a sharp col d kni fe, cut urethane adhe-
si ve hol di ng the wi ndshi el d to the A-pi l l ars, roof
header and cowl pi nch wel d fences (Fi g. 2). A power
cutti ng devi ce can be used i f avai l abl e.
(9) Remove wi ndshi el d from vehi cl e.
23 - 4 BODY NS
WINDSHIELD REMOVAL INTERIOR METHOD
(1) Remove i nsi de rear vi ew mi rror.
(3) Remove A-pi l l ar tri m covers.
(4) Di sconnect wi re connectors to wi ndshi el d
defroster gri d.
(5) Pl ace protecti ve covers over i nstrument panel
and hood.
(6) Usi ng a reci procati ng or osci l l ati ng power
kni fe, cut urethane adhesi ve hol di ng the wi ndshi el d
to the A-pi l l ars, roof header and cowl pi nch wel d
fences. Refer to i nstructi ons provi ded wi th the equi p-
ment bei ng used.
(7) Remove wi ndshi el d from vehi cl e.
WINDSHIELD INSTALLATION
CAUTION: Open the left front door glass before
installing windshield to avoid pressurizing the pas-
senger compartment. If a door is slammed before
urethane bonding is cured, water leaks can result.
Allow the urethane at least 24 hours to cure
before returning the vehicle to use.
To avoid stressing the replacement windshield,
the urethane bonding material on the windshield
fence should be smooth and consistent to the
shape of the replacement windshield. The support
spacers should be cleaned and properly installed
on weld studs or repair screws at bottom of wind-
shield opening.
(1) Pl ace repl acement wi ndshi el d i nto wi ndshi el d
openi ng and posi ti on gl ass i n the center of the open-
i ng agai nst the support spacers.
(2) Veri fy the gl ass l ays evenl y agai nst the pi nch
wel d fence at the si des, top and bottom of the
repl acement wi ndshi el d. I f not, the pi nch wel d fence
must be formed to the shape of the new gl ass.
(3) Mark the gl ass at the support spacers wi th a
grease penci l or pi eces of maski ng tape and i nk pen
to use as a reference for i nstal l ati on (Fi g. 3).
(4) Remove repl acement wi ndshi el d from wi nd-
shi el d openi ng.
(5) Posi ti on the wi ndshi el d i nsi de up on a sui tabl e
work surface wi th two padded, wood 10 cm by 10 cm
by 50 cm (4 i n. by 4 i n. by 20 i n.) bl ocks, pl aced par-
al l el 75 cm (2.5 ft.) apart (Fi g. 4).
WARNING: DO NOT USE SOLVENT BASED GLASS
CLEANER TO CLEAN WINDSHIELD BEFORE
APPLYING GLASS PREP AND PRIMER. POOR
ADHESION CAN RESULT.
(6) Cl ean i nsi de of wi ndshi el d wi th ammoni a based
gl ass cl eaner and l i nt-free cl oth.
(7) I nstal l mol di ng to peri meter of wi ndshi el d.
(8) Appl y Gl ass Prep adhesi on promoter 25 mm (1
i n.) wi de around peri meter of wi ndshi el d and wi pe
wi th cl ean/dry l i nt-free cl oth unti l no streaks are vi s-
i bl e.
(9) Appl y Gl ass Pri mer 25 mm (1 i n.) wi de around
peri meter of wi ndshi el d. Al l ow at l east three mi nutes
dryi ng ti me.
(10) Usi ng a razor kni fe, remove as much ori gi nal
urethane as possi bl e. Do not damage pai nt on wi nd-
shi el d fence.
(11) Appl y pi nch wel d pri mer 15 mm (.75 i n.) wi de
around the wi ndshi el d fence. Al l ow at l east three
mi nutes dryi ng ti me.
(12) I f a l ow vi scosi ty urethane adhesi ve i s used,
i nstal l compressi on spacers on the fence around the
wi ndshi el d openi ng (Fi g. 5).
(13) Appl y a 10 mm (0.4 i n.) bead of urethane on
center l i ne of wi ndshi el d fence.
(14) Wi th the ai d of a hel per, posi ti on the wi nd-
shi el d over the wi ndshi el d openi ng. Al i gn the refer-
ence marks at the bottom of the wi ndshi el d to the
support spacers.
(15) Sl owl y l ower wi ndshi el d gl ass to wi ndshi el d
openi ng fence. Gui de the mol di ng i nto proper posi ti on
as necessary. Push wi ndshi el d i nward unti l mol di ng
i s fl ush to roof l i ne and A-pi l l ars (Fi g. 5).
Fig. 1 Windshield Molding
Fig. 2 Cut Urethane Around Windshield
NS BODY 23 - 5
(16) Cl ean access urethane from exteri or wi th
Mopar Super Kl een or equi val ent.
(17) Appl y 150 mm (6 i n.) l engths of 50 mm (2 i n.)
maski ng tape spaced 250 mm (10 i n.) apart to hol d
mol di ng i n pl ace unti l urethane cures.
(18) Engage wi re connectors to wi ndshi el d
defroster gri d.
(19) I nstal l A-pi l l ar tri m panel s.
(20) I nstal l cowl cover and wi pers.
(21) I nstal l i nsi de rear vi ew mi rror.
(22) After urethane has cured, remove tape stri ps
and water test wi ndshi el d to veri fy repai r.
BODY SIDE/SLIDING DOOR STATIONARY GLASS
The temperature of the vehi cl e shoul d be at l east
21 C (70 F) before removi ng the stati onary quarter/
sl i di ng door gl ass. Butyl seal er becomes more pl i abl e
at hi gh temperatures.
REMOVAL
(1) Remove i nteri or tri m as necessary to gai n
access attachi ng l ocati ons on back of gl ass.
(2) Remove nuts hol di ng stati onary gl ass to fence.
(3) Usi ng razor kni fe, cut butyl seal er hol di ng
gl ass to fence from between the mounti ng studs (Fi g.
6).
(4) Push gl ass from openi ng.
INSTALLATION
The stati onary gl ass fence shoul d be cl eaned of al l
ol d butyl seal er.
(1) Appl y a 6 mm (0.25 i n.) butyl tape around
peri meter of gl ass assembl y encapsul ati on track.
Ensure that the butyl tape i s wrapped around the
mounti ng studs.
(2) Pl ace the gl ass i nto the openi ng and i nsert
mounti ng studs through hol es i n fence.
(3) I nstal l nuts to hol d stati onary gl ass to fence.
Fig. 3 Center Windshield and Mark at Support
Spacers
Fig. 4 Work Surface Set up and Molding Installation
Fig. 5 Lower Windshield Into Position
Fig. 6 Sliding Door Stationary Glass
23 - 6 BODY NS
NOTE: Tighten nuts to 3.4 Nm (30 in. lbs.) torque
in the sequence indicated. Do not over torque, or
glass breakage may result (Fig. 6).
(4) I nstal l i nteri or tri m.
REAR WINDOW
Refer to the Safety Precauti ons i n thi s secti on for
descri pti on of tool s and adhesi ve systems that are
recommended for use i n thi s procedure.
REAR WINDOW REMOVAL EXTERIOR
METHOD
(1) Remove rear wi ndow wi per arm, i f equi pped.
(2) Remove screws hol di ng mol di ngs to l i ftgate at
the si des of the rear wi ndow (Fi g. 7).
(3) Usi ng pl i ers, pul l outward on mol di ng at the
top and bottom of l i ftgate.
(4) Usi ng a sharp col d kni fe, cut urethane adhe-
si ve hol di ng the rear wi ndow to the l i ftgate. A power
cutti ng devi ce can be used i f avai l abl e (Fi g. 2).
(5) Remove rear wi ndow from vehi cl e.
REAR WINDOW REMOVAL INTERIOR
METHOD
(1) Remove rear wi ndow wi per arm, i f equi pped.
(2) Remove screws hol di ng mol di ngs to l i ftgate at
the si des of the rear wi ndow (Fi g. 7).
(3) Remove l i ftgate i nsi de l amps and tri m covers.
(4) Remove center hi gh mounted stop l amp.
(5) Usi ng a reci procati ng or osci l l ati ng power
kni fe, cut urethane adhesi ve hol di ng the rear wi ndow
to the l i ftgate. Refer to i nstructi ons provi ded wi th
the equi pment bei ng used.
(6) Remove rear wi ndow from vehi cl e.
REAR WINDOW INSTALLATION
CAUTION: Open the left front door glass before
installing rear window to avoid pressurizing the
passenger compartment. If a door is slammed
before urethane bonding is cured, water leaks can
result.
Allow the urethane at least 24 hours to cure
before returning the vehicle to use.
To avoid stressing the replacement rear window,
the urethane bonding material on the rear window
fence should be smooth and consistent to the
shape of the replacement glass.
(1) Pl ace repl acement gl ass i nto rear wi ndow open-
i ng.
(2) Veri fy the gl ass l ays evenl y agai nst the pi nch
wel d fence at the si des, top and bottom of the
repl acement rear wi ndow. I f not, the fence must be
formed to the shape of the new gl ass.
(3) Usi ng a grease penci l , mark the gl ass and l i ft-
gate i n several l ocati ons to ai d i nstal l ati on.
(4) Remove repl acement gl ass from l i ftgate open-
i ng.
(5) Posi ti on the rear wi ndow i nsi de up on a sui t-
abl e work surface wi th two padded, wood 10 cm by
10 cm by 50 cm (4 i n. by 4 i n. by 20 i n.) bl ocks,
pl aced paral l el 75 cm (2.5 ft.) apart (Fi g. 4).
WARNING: DO NOT USE SOLVENT BASED GLASS
CLEANER TO CLEAN REAR WINDOW BEFORE
APPLYING GLASS PREP AND PRIMER. POOR
ADHESION CAN RESULT.
(6) Cl ean i nsi de of rear wi ndow wi th ammoni a
based gl ass cl eaner and l i nt-free cl oth.
(7) Appl y mol di ng to top and bottom of rear wi n-
dow.
(8) Appl y Gl ass Prep adhesi on promoter 25 mm (1
i n.) wi de around peri meter of rear wi ndow and wi pe
wi th cl ean/dry l i nt-free cl oth unti l no streaks are vi s-
i bl e.
(9) Appl y Gl ass Pri mer 25 mm (1 i n.) wi de around
peri meter of rear wi ndow. Al l ow at l east three mi n-
utes dryi ng ti me.
(10) Appl y Pi nchwel d Pri mer 15 mm (.75 i n.) wi de
around the rear wi ndow fence. Al l ow at l east three
mi nutes dryi ng ti me.
(11) I f a l ow vi scosi ty urethane adhesi ve i s used,
i nstal l compressi on spacers on the fence around the
rear wi ndow openi ng (Fi g. 8).
(12) Appl y a 10 mm (0.4 i n.) bead of urethane
al ong center l i ne of rear wi ndow fence.
Fig. 7 Rear Window Side Moldings
NS BODY 23 - 7
(13) Wi th the ai d of a hel per, posi ti on the rear
wi ndow over the rear wi ndow openi ng and al i gn the
reference marks.
(14) Sl owl y l ower the gl ass to rear wi ndow openi ng
fence. Gui de the mol di ng i nto proper posi ti on as nec-
essary. Push gl ass i nward unti l mol di ng i s fl ush to
l i ftgate surface (Fi g. 8).
(15) Cl ean excess urethane from exteri or wi th
Mopar Super Kl een, or equi val ent.
(16) Appl y 150 mm (6 i n.) l engths of 50 mm (2 i n.)
maski ng tape spaced 250 mm (10 i n.) apart to hol d
mol di ng i n pl ace unti l urethane cures.
(17) I nstal l rear wi ndow si de mol di ngs and wi per
arm (Fi g. 7).
(18) I nstal l i nteri or tri m.
(19) After urethane has cured, remove tape stri ps
and water test rear wi ndow to veri fy repai r. Fig. 8 Lower Rear Window Into Position
23 - 8 BODY NS
SEATS
INDEX
page page
ARM REST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
BENCH SEAT BACK COVER . . . . . . . . . . . . . . . . 9
BENCH SEAT BACK HINGE COVERS . . . . . . . . 10
BENCH SEAT BACK HINGE . . . . . . . . . . . . . . . . . 9
BENCH SEAT RISER FIRST REAR . . . . . . . . . 11
BENCH SEAT RISER SECOND REAR . . . . . . . 11
BENCH SEAT TRACK SECOND REAR . . . . . . 11
BUCKET SEAT BACK ASSIST STRAP . . . . . . . . 12
BUCKET SEAT BACK . . . . . . . . . . . . . . . . . . . . . 12
BUCKET SEAT CUSHION PAN . . . . . . . . . . . . . . 12
BUCKET SEAT CUSHION SIDE COVER . . . . . . . 13
BUCKET SEAT RECLINER MANUAL . . . . . . . . 13
BUCKET SEAT RECLINER POWER . . . . . . . . . 14
BUCKET SEAT RISER MANUAL TRACK . . . . . 14
BUCKET SEAT TRACK FRONT COVER
POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
BUCKET SEAT TRACK REAR COVER
POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
BUCKET SEAT TRACK MANUAL . . . . . . . . . . . 14
BUCKET SEAT TRACK POWER . . . . . . . . . . . 14
CHILD RESTRAINT SEAT MODULE . . . . . . . . . . 16
HEAD RESTRAINT SLEEVE . . . . . . . . . . . . . . . . 18
HEAD RESTRAINT BENCH SEAT . . . . . . . . . . 16
HEAD RESTRAINT BUCKET SEAT . . . . . . . . . 17
HEATED SEAT HEATING ELEMENT . . . . . . . . . . 18
HEATED SEAT MODULE . . . . . . . . . . . . . . . . . . 18
HEATED SEAT SWITCH . . . . . . . . . . . . . . . . . . . 19
MECHANICAL LUMBAR HANDLE ASSEMBLY . . 19
PLASTIC GROCERY BAG RETAINER . . . . . . . . . 19
POWER SEAT SWITCH . . . . . . . . . . . . . . . . . . . 20
RECLINER HANDLE MANUAL . . . . . . . . . . . . . 20
UNDER SEAT STORAGE BIN GUIDE . . . . . . . . . 21
UNDER SEAT STORAGE BIN LOCK/LATCH . . . . 21
UNDER SEAT STORAGE BIN . . . . . . . . . . . . . . . 20
ARM REST
REMOVAL
(1) Usi ng a screw dri ver, pry cap from si de of arm
rest (Fi g. 1).
(2) Remove bol t hol di ng arm rest to seat back.
(3) Remove arm rest from seat.
INSTALLATION
(1) Pl ace arm rest i n posi ti on on seat.
(2) I nstal l bol t to hol d arm rest to seat back.
(3) I nstal l cap i nto si de of arm rest (Fi g. 1).
BENCH SEAT BACK COVER
REMOVAL
(1) Remove pl asti c grocery bag retai ner attachi ng
screws and remove retai ner.
(2) Usi ng a fork type pryi ng tool (C4829), di sen-
gage push-i n fasteners hol di ng bottom of seat back
cover to seat back frame (Fi g. 2).
(3) Di sengage hooks hol di ng top of seat back cover
to seat back frame.
(4) Remove seat back cover from seat.
INSTALLATION
(1) Pl ace seat back cover i n posi ti on on seat.
(2) Engage hooks to hol d top of seat back cover to
seat back frame.
(3) I nstal l push-i n fasteners to hol d bottom of seat
back cover to seat back frame (Fi g. 2).
BENCH SEAT BACK HINGE
Bench seats equi pped wi th chi l d restrai nt seats
have an i nterl ock feature that wi l l not al l ow the seat
back to fol d forward wi th the chi l d seat open.
REMOVAL
(1) Remove bench seat back hi nge covers.
(2) Remove shoul der bol ts hol di ng seat back hi nge
to seat back frame (Fi g. 3).
(3) Remove bol ts hol di ng seat back hi nge to seat
cushi on frame.
Fig. 1 Arm Rest
NS BODY 23 - 9
(4) Remove seat back hi nge from seat.
(5) Di sengage synchroni zi ng cabl e housi ng from
seat back hi nge.
(6) Di sengage synchroni zi ng cabl e end from (cl i p
on l eft si de) hi nge l atch rel ease arm.
(7) Remove hi nge from seat.
INSTALLATION
(1) Pl ace hi nge i n posi ti on on seat.
(2) Engage synchroni zi ng cabl e end i nto (cl i p on
l eft si de) hi nge l atch rel ease arm.
(3) Engage synchroni zi ng cabl e housi ng i nto seat
back hi nge.
(4) Pl ace seat back hi nge i n posi ti on on seat.
(5) I nstal l bol ts to hol d seat back hi nge to seat
cushi on frame.
(6) I nstal l shoul der bol ts to hol d seat back hi nge to
seat back frame (Fi g. 3).
(7) I nstal l bench seat back hi nge covers.
(8) Veri fy seat back hi nge operati on.
SYNCHRONIZING CABLE ADJ USTMENT
I f the seat back hi nges do not rel ease at the same
ti me the synchroni zi ng cabl e must be adjusted.
(1) Remove seat from vehi cl e. Refer to Owners
Manual for proper procedures (Fi g. 4).
(2) Usi ng a awl , pry synchroni zi ng cabl e end from
cl i p on l eft seat back hi nge.
(3) Pul l cabl e out of housi ng unti l cabl e i s ti ght.
(4) Push retai ni ng cl i p on hi nge l atch rel ease arm
rearward to take up pl ay i n hi nge mechani sm.
(5) Engage cabl e end i nto retai ni ng cl i p on hi nge.
BENCH SEAT BACK HINGE COVERS
REMOVAL
(1) I f necessary, remove seat from vehi cl e. Refer to
Owners Manual for proper procedures.
(2) Remove screws hol di ng l ower cover to seat
back hi nge (Fi g. 5).
(3) Remove l ower cover from hi nge.
(4) Remove screws hol di ng upper hi nge cover to
seat back hi nge.
(5) Remove upper cover from seat back hi nge.
INSTALLATION
(1) Pl ace upper cover i n posi ti on on seat back
hi nge.
(2) I nstal l screws to hol d upper hi nge cover to seat
back hi nge.
(3) Pl ace l ower cover i n posi ti on on hi nge.
(4) I nstal l screws to hol d l ower cover to seat back
hi nge (Fi g. 5).
(5) I f necessary, i nstal l seat i n vehi cl e.
Fig. 2 Bench Seat Back Cover
Fig. 3 Bench Seat Back Hinge
Fig. 4 SYNCHRONIZING CABLE ADJUSTMENT
23 - 10 BODY NS
BENCH SEAT RISER FIRST REAR
REMOVAL
(1) Remove fi rst rear seat from vehi cl e. Refer to
(2) Pl ace seat bottom si de up on a cl ean covered
work surface.
(3) Remove bol ts hol di ng seat ri ser to seat cushi on
frame (Fi g. 6).
(4) Remove ri ser from seat.
INSTALLATION
(1) Pl ace ri ser i n posi ti on on seat.
(2) I nstal l bol ts to hol d seat ri ser to seat cushi on
frame (Fi g. 6).
(3) I nstal l fi rst rear seat i nto vehi cl e.
BENCH SEAT RISER SECOND REAR
REMOVAL
(1) Remove seat track.
(2) Remove bol ts hol di ng ri ser to seat cushi on
frame (Fi g. 7).
INSTALLATION
(2) I nstal l bol ts to hol d ri ser to seat cushi on frame
(Fi g. 7).
(3) I nstal l seat track.
BENCH SEAT TRACK SECOND REAR
REMOVAL
(1) Remove second rear seat from vehi cl e. Refer to
Owners Manual for proper procedure.
(2) Pl ace seat on cl ean covered work surface bot-
tom si de up.
(3) Di sengage seat track adjuster l i nk wi re from
track bei ng removed.
(4) Remove nuts hol di ng track to seat ri ser (Fi g.
8).
(5) Remove track from seat ri ser.
INSTALLATION
(1) Pl ace track i n posi ti on on seat ri ser.
(2) I nstal l nuts to hol d track to seat ri ser. (Fi g. 8).
(3) Engage seat track adjuster l i nk wi re onto track
bei ng i nstal l ed.
(4) I nstal l second rear seat from vehi cl e.
Fig. 5 Bench Seat Back Hinge Covers
Fig. 6 Bench Seat Riser First Rear
Fig. 7 Bench Seat Riser Second Rear
NS BODY 23 - 11
BUCKET SEAT BACK
REMOVAL
(1) Remove seat cushi on pan.
(2) Remove nut hol di ng recl i ner to seat back frame
(Fi g. 9).
(3) Remove pi vot bol ts hol di ng seat back frame to
seat track.
(4) Remove seat back from recl i ner.
INSTALLATION
(1) Pl ace seat back mounti ng stud i nto recl i ner.
(2) I nstal l pi vot bol ts to hol d seat back frame to
seat track.
(3) I nstal l nut to hol d recl i ner to seat back frame
(Fi g. 9).
(4) I nstal l seat cushi on pan.
BUCKET SEAT BACK ASSIST STRAP
REMOVAL
(1) Usi ng a smal l screw dri ver, pry screw pl ugs
from ends of assi st strap (Fi g. 10).
(2) Remove screws hol di ng assi st strap to seat
back.
(3) Remove assi st strap from vehi cl e.
INSTALLATION
(1) Pl ace assi st strap i n posi ti on on vehi cl e.
(2) I nstal l screws to hol d assi st strap to seat back.
(3) I nsert screw pl ugs i nto ends of assi st strap
(Fi g. 10).
BUCKET SEAT CUSHION PAN
REMOVAL
(1) Remove bucket seat from vehi cl e.
(2) Remove seat cushi on si de covers.
(3) I f equi pped, remove power seat track front and
rear cover.
(4) I f equi pped, remove stowage bi n.
(5) Remove bol ts hol di ng seat cushi on pan to seat
track.
(6) Remove seat cushi on pan from seat.
(7) Di sengage J-stri p retai ners hol di ng seat cover
to cushi on pan.
(8) Separate seat cushi on pan from cover and pad.
Fig. 8 Bench Seat Track Second Rear
Fig. 9 Bucket Seat Back
Fig. 10 Bucket Seat Back Assist Strap
23 - 12 BODY NS
INSTALLATION
(1) Pl ace seat cushi on pan i n posi ti on i n seat cover
and pad.
(2) Engage J-stri p retai ners to hol d seat cover to
cushi on pan.
(3) Pl ace seat cushi on pan i n posi ti on on seat.
(4) I nstal l bol ts to hol d seat cushi on pan to seat
track.
(5) I f equi pped, i nstal l stowage bi n.
(6) I f equi pped, i nstal l power seat track front and
rear cover.
(7) I nstal l seat cushi on si de covers.
(8) I nstal l bucket seat i n vehi cl e.
BUCKET SEAT CUSHION SIDE COVER
REMOVAL
(1) Remove screws hol di ng seat cushi on si de cover
to bucket seat (Fi g. 11).
(2) Sl i de seat cushi on rear l i sti ng toward the cen-
ter of the seat to gai n access to rear screw.
(3) Remove screw hol di ng rear of si de cover to seat
cushi on frame.
(4) Remove si de cover from seat cushi on.
(5) I f equi pped, di sconnect wi re connector from
power seat swi tch (Fi g. 12).
INSTALLATION
(1) Pl ace si de cover i n posi ti on on seat cushi on.
(2) I f equi pped, connect wi re connector i nto power
seat swi tch.
(3) I nstal l screw to hol d rear of si de cover to seat
cushi on frame.
(4) I nstal l screws to hol d seat cushi on si de cover to
bucket seat (Fi g. 11).
BUCKET SEAT RECLINER MANUAL
REMOVAL
(1) Remove bucket seat cushi on pan.
(2) Remove E-cl i p hol di ng pi n i n seat track.
(3) Remove pi n hol di ng manual recl i ner to seat
track (Fi g. 13).
(4) Remove nut hol di ng recl i ner to seat back
frame.
(5) Remove recl i ner from seat.
INSTALLATION
(1) Pl ace recl i ner i n posi ti on on seat.
(2) I nsert stud on seat back through hol e i n
recl i ner.
(3) I nstal l nut to hol d recl i ner to seat back frame.
(4) I nstal l rol l pi n to hol d manual recl i ner to seat
track (Fi g. 13).
(5) I nstal l E-cl i p to hol d pi n i n seat track.
(6) I nstal l bucket seat cushi on pan.
Fig. 11 Bucket Seat Cushion Side Cover
Fig. 12 Power Seat Switch Wire Connector
Fig. 13 Bucket Seat Recliner Manual
NS BODY 23 - 13
BUCKET SEAT RECLINER POWER
REMOVAL
(2) Remove nut hol di ng seat back frame to
recl i ner.
(3) Usi ng a sui tabl e punch, remove rol l pi n hol di ng
recl i ner to seat track (Fi g. 14).
(4) Remove recl i ner from seat track.
(5) Remove recl i ner from stud on seat back frame.
(6) Di sconnect wi re connector from power recl i ner.
(7) Remove power recl i ner from seat.
INSTALLATION
(1) Pl ace power recl i ner i n posi ti on on seat.
(2) Connect wi re connector i nto power recl i ner.
(3) I nsert stud on seat back through hol e i n
recl i ner.
(4) Pl ace recl i ner i n posi ti on on seat track.
(5) I nstal l rol l pi n to attach recl i ner to seat track
(Fi g. 14).
(6) I nstal l nut to hol d seat back frame to recl i ner.
BUCKET SEAT RISER MANUAL TRACK
REMOVAL
(1) Remove seat from vehi cl e.
(2) I f equi pped, remove storage bi n from ri ser.
(3) Remove nuts hol di ng ri ser to manual seat
track (Fi g. 15).
INSTALLATION
(2) I nstal l nuts to hol d ri ser to manual seat track
(Fi g. 15).
(3) I f equi pped, i nstal l storage bi n i nto ri ser.
(4) I nstal l seat i nto vehi cl e.
BUCKET SEAT TRACK MANUAL
REMOVAL
(3) Remove ri ser.
(4) On i nboard track, remove nut hol di ng recl i ner
to seat back frame.
(5) Remove bol t hol di ng seat back frame to seat
track (Fi g. 16).
(6) Remove seat track from seat adjuster handl e
(Fi g. 17).
(7) Remove seat track from seat.
INSTALLATION
(1) Pl ace seat track i n posi ti on on seat.
(2) Pl ace adjuster handl e i n posi ti on on seat track
(Fi g. 17).
(3) I nsert stud on seat back frame i nto recl i ner.
(4) I nstal l bol t to hol d seat back frame to seat
track (Fi g. 16).
(5) On i nboard track, i nstal l nut to hol d recl i ner to
seat back frame.
(6) I nstal l ri ser.
(8) I nstal l seat i n vehi cl e.
BUCKET SEAT TRACK POWER
The power seat track and motors are servi ced as
an assembl y.
REMOVAL
(3) Remove nut hol di ng recl i ner to seat back
frame.
(4) Remove bol ts hol di ng seat back frame to seat
track.
(5) Remove stud on seat back frame from recl i ner.
Fig. 14 Bucket Seat Recliner Power
Fig. 15 Bucket Seat Riser Manual Track
23 - 14 BODY NS
(6) Remove seat back from recl i ner.
INSTALLATION
I f power seat track i s bei ng repl aced, transfer
power recl i ner, wi re harness and tri m covers to
repl acement seat track.
(1) I nsert stud on seat back frame i nto recl i ner.
(2) I nstal l bol ts to hol d seat back frame to seat
track.
(3) I nstal l nut to hol d recl i ner to seat back frame.
(5) I nstal l seat i n vehi cl e.
BUCKET SEAT TRACK FRONT COVER POWER
REMOVAL
(1) Remove screws hol di ng front cover to seat
track (Fi g. 18).
(2) Remove front cover from vehi cl e.
INSTALLATION
(1) Pl ace front cover i n posi ti on on seat.
(2) I nstal l screws to hol d front cover to seat track
(Fi g. 18).
BUCKET SEAT TRACK REAR COVER POWER
REMOVAL
(1) Di sengage arrowhead retai ner from l oop stri p
hol di ng rear cover to power seat track crossbar (Fi g.
19).
(2) Di sengage fasteners hol di ng rear cover to sl ots
on power seat track.
(3) Remove rear cover from seat.
INSTALLATION
(1) Pl ace rear cover i n posi ti on on seat.
(2) Engage fasteners to hol d rear cover to sl ots on
power seat track.
(3) Engage arrowhead retai ner i nto l oop stri p to
hol d rear cover to power seat track crossbar (Fi g. 19).
Fig. 16 Bucket Seat Track Manual
Fig. 17 Seat Track Adjuster Handle
Fig. 18 Bucket Seat Track Front Cover Power
NS BODY 23 - 15
CHILD RESTRAINT SEAT MODULE
REMOVAL
(1) Cl ose chi l d restrai nt seat.
(2) Remove seat back cover.
(3) Remove screws hol di ng chi l d restrai nt seat
modul e hi nges to seat back frame l ower rai l (Fi g. 20).
(4) Return seat back to upri ght posi ti on.
(5) Di sengage push-i n fasteners hol di ng upper bol -
ster to chi l d restrai nt seat modul e (Fi g. 21).
(6) Remove screws hol di ng top of modul e to seat
back frame upper rai l (Fi g. 22).
(7) Remove chi l d restrai nt seat modul e from seat
back (Fi g. 23).
INSTALLATION
(1) Pl ace chi l d restrai nt seat modul e i n posi ti on on
seat back (Fi g. 23).
(2) Posi ti on seat back hi nge i nterl ock l ever over
the top of the outboard chi l d restrai nt seat hi nge
(Fi g. 24).
(3) I nstal l screws to hol d chi l d restrai nt seat mod-
ul e hi nges to seat back frame l ower rai l (Fi g. 20).
(4) I nstal l screws to hol d top of modul e to seat
back frame upper rai l (Fi g. 22).
(5) I nstal l push-i n fasteners to hol d upper bol ster
to chi l d restrai nt seat modul e (Fi g. 21).
(6) Return seat back to fol ded posi ti on.
(7) I nstal l seat back cover.
(8) Veri fy chi l d restrai nt seat operati on.
HEAD RESTRAINT BENCH SEAT
REMOVAL
(1) Li ft head restrai nt to top of travel .
(2) Remove escutcheon from head restrai nt sl eeve.
(3) Usi ng a smal l screw dri ver, depress retai ner
i nward to rel ease head restrai nt (Fi g. 25).
(4) Pul l head restrai nt from top of seat back (Fi g.
26).
Fig. 19 Bucket Seat Track Rear Cover Power
Fig. 20 Child Restraint Seat Lower Hinge
Fig. 21 Child Restraint Seat Upper Bolster
Fig. 22 Child Restraint Seat Upper Screws
23 - 16 BODY NS
INSTALLATION
(1) I nsert retai ner and escutcheon i nto head
restrai nt sl eeve (Fi g. 27).
(2) I nsert head restrai nt i nto sl eeve. The l ock but-
ton must be depressed to l ower the head rest.
HEAD RESTRAINT BUCKET SEAT
REMOVAL
(2) Depress l ock button on si de of sl eeve at top of
(3) Pul l head restrai nt from top of seat back.
Fig. 23 Child Restraint Seat Module
Fig. 24 Interlock Lever
Fig. 25 Head Restraint Sleeve Escutcheon
Fig. 26 Release Retainer
Fig. 27 Install Retainer and Escutcheon
NS BODY 23 - 17
INSTALLATION
HEAD RESTRAINT SLEEVE
REMOVAL
(1) Remove head restrai nt.
(2) Di sengage cl osure hol di ng bottom of tri m cover
together.
(3) Reach under tri m cover through openi ng at
bottom of seat back.
(4) Pi nch retai ner barbs on end of head restrai nt
sl eeve together (Fi g. 29).
(5) Pul l head restrai nt sl eeve upward and out the
top of the seat back frame gui de tube (Fi g. 30).
INSTALLATION
(1) I nsert head restrai nt sl eeve i nto gui de tube at
top of seat back.
(2) Push head restrai nt sl eeve downward unti l
retai ner cl i cks i nto l ock posi ti on.
(3) Engage cl osure to hol d bottom of tri m cover
together.
(4) I nstal l head restrai nt.
HEATED SEAT HEATING ELEMENT
Di agnosti c i nformati on for heated seat heati ng el e-
ment i s l ocated i n Group 8R, Power Seats.
The heati ng el ements are sewn i nto the covers. To
repl ace a heati ng el ement the cushi on or back tri m
covers need to be repl aced.
HEATED SEAT MODULE
Di agnosti c i nformati on for heated seat modul e i s
l ocated i n Group 8R, Power Seats.
REMOVAL
(1) Remove four bol ts attachi ng seat to the fl oor
pan. Ti p seat forward to access the heated seat mod-
ul e.
(2) Di sconnect wi re connectors from heated seat
modul e.
(3) Pry power seat swi tch knobs strai ght off
swi tch.
(4) Remove screws attachi ng modul e to the seat
pan.
(5) Remove heated seat modul e.
Fig. 28 Head Restraint Bucket Seat
Fig. 29 Head Restraint Sleeve Retainer
Fig. 30 Head Restraint Sleeve
23 - 18 BODY NS
INSTALLATION
(1) Pl ace heated seat modul e i n posi ti on on seat
pan.
(2) I nstal l modul e attachi ng screws.
(3) Connect modul e wi re connectors.
(4) I nstal l seat.
HEATED SEAT SWITCH
Di agnosti c i nformati on for heated seat swi tch i s
REMOVAL
(1) Remove i nboard si de cover (Fi g. 31) and (Fi g.
32).
(2) Di sconnect wi re connector from heated seat
swi tch.
(3) Careful l y depress l ocki ng l egs on swi tch and
push swi tch free of cover.
INSTALLATION
(1) Pl ace heated seat swi tch i n posi ti on on si de
cover.
(2) Press swi tch i nto l ocked posi ti on.
(3) Connect wi re connector i nto heated seat swi tch.
(4) I nstal l i nboard si de cover.
MECHANICAL LUMBAR HANDLE ASSEMBLY
REMOVAL
(1) Remove screw attachi ng l umbar handl e to seat
back (Fi g. 33).
(2) Remove seat back assembl y from cushi on.
(3) Detri m the seat back assembl y.
(4) Remove frame and repl ace.
INSTALLATION
(1) Tri m the seat back frame.
(2) I nstal l seat back assembl y to cushi on.
(3) I nstal l attachi ng screw to l umbar handl e. The
handl e i s to be i nstal l ed, between two and three
Ocl ock posi ti on.
(4) Test l umbar operati on.
PLASTIC GROCERY BAG RETAINER
REMOVAL
(1) Remove fi ve screws attachi ng the pl asti c gro-
cery bag retai ner to the steel sl ates on the back
frame (Fi g. 34).
(2) Remove retai ner.
INSTALLATION
(1) Pl ace retai ner i n posi ti on.
(2) I nstal l attachi ng screws.
Fig. 31 Right Heated Seat Switch
Fig. 32 Left Heated Seat Switch
Fig. 33 Lumbar Handle
Fig. 34 Plastic Grocery Bag Retainer
NS BODY 23 - 19
POWER SEAT SWITCH
Di agnosti c i nformati on for power seat swi tch i s
REMOVAL
(1) Remove seat cushi on si de cover.
(2) Di sconnect wi re connector from power seat
swi tch.
(3) Pry power seat swi tch knobs strai ght off swi tch
(Fi g. 35).
(4) Remove screws hol di ng power seat swi tch to
si de cover (Fi g. 36).
(5) Remove power seat swi tch from si de cover.
INSTALLATION
(1) Pl ace power seat swi tch i n posi ti on on si de
cover.
(2) I nstal l screws to hol d power seat swi tch to si de
cover (Fi g. 36).
(3) Push power seat swi tch knobs strai ght on
swi tch (Fi g. 35).
(4) Connect wi re connector i nto power seat swi tch.
(5) I nstal l seat cushi on si de cover.
RECLINER HANDLE MANUAL
REMOVAL
(1) Remove screw hol di ng recl i ner handl e to
recl i ner spl i ne shaft (Fi g. 37).
(2) Remove recl i ner handl e from spl i ne shaft.
INSTALLATION
(1) Pl ace recl i ner handl e i n posi ti on on spl i ne
shaft.
(2) I nstal l screw to hol d recl i ner handl e to recl i ner
spl i ne shaft (Fi g. 37).
UNDER SEAT STORAGE BIN
REMOVAL
(1) Rel ease under seat storage bi n l atch and open
bi n.
(2) Depress l ock tabs at the rear/top edge of the
storage bi n (Fi g. 38).
(3) Pul l storage bi n from bucket seat ri ser.
INSTALLATION
(1) Engage storage bi n tracks i nto gui des on each
si de of seat ri ser.
(2) Push storage bi n i nward unti l l ock tabs snap
past retai ni ng ri dge on tracks
(3) Veri fy storage bi n l atch operati on.
Fig. 35 Power Seat Switch Knobs
Fig. 36 Power Seat Switch
Fig. 37 Recliner Handle Manual
23 - 20 BODY NS
UNDER SEAT STORAGE BIN GUIDE
REMOVAL
(1) Remove under seat storage bi n.
(2) Remove screws hol di ng storage bi n track gui de
to seat ri ser (Fi g. 39).
(3) Remove track gui de from vehi cl e.
INSTALLATION
(1) Pl ace track gui de i n posi ti on on seat ri ser.
(2) I nstal l screws to hol d storage bi n track gui de to
seat ri ser (Fi g. 39).
(3) I nstal l under seat storage bi n.
UNDER SEAT STORAGE BIN LOCK/LATCH
REMOVAL
(1) Open under seat storage bi n.
(2) Remove screws hol di ng under seat storage bi n
l ock/l atch to storage bi n (Fi g. 40).
(3) Remove l ock/l atch from bi n.
INSTALLATION
(1) Pl ace l ock/l atch i n posi ti on on storage bi n.
(2) I nstal l screws to hol d l ock/l atch to storage bi n
(Fi g. 40).
(3) Veri fy under seat storage bi n l atch operati on.
Fig. 38 Storage Bin Fig. 39 Under Seat Storage Bin Guide
Fig. 40 Under Seat Storage Bin Lock/Latch
NS BODY 23 - 21
BODY COMPONENT SERVICE
INDEX
page page
WATER LEAKS . . . . . . . . . . . . . . . . . . . . . . . . . . 23
WIND NOISE . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
SERVICE PROCEDURES
HEAT STAKING . . . . . . . . . . . . . . . . . . . . . . . . . 24
A-PILLAR LOWER EXTENSION TRIM . . . . . . . . 25
A-PILLAR TRIM PANEL . . . . . . . . . . . . . . . . . . . 25
COWL COVER . . . . . . . . . . . . . . . . . . . . . . . . . . 25
COWL TRIM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
FLOOR CARPET . . . . . . . . . . . . . . . . . . . . . . . . 26
FRONT DOOR APPLIQUE . . . . . . . . . . . . . . . . . 28
FRONT DOOR CHECK STRAP . . . . . . . . . . . . . . 28
FRONT DOOR FRAME CLOSEOUT MOLDINGS . 29
FRONT DOOR GLASS RUN WEATHER-STRIP . . 30
FRONT DOOR GLASS . . . . . . . . . . . . . . . . . . . . 29
FRONT DOOR HINGE . . . . . . . . . . . . . . . . . . . . 30
FRONT DOOR INNER BELT MOLDING . . . . . . . 31
FRONT DOOR LATCH STRIKER . . . . . . . . . . . . 32
FRONT DOOR LATCH . . . . . . . . . . . . . . . . . . . . 31
FRONT DOOR LOCK CYLINDER . . . . . . . . . . . . 32
FRONT DOOR OUTER BELT MOLDING . . . . . . . 33
FRONT DOOR OUTSIDE HANDLE . . . . . . . . . . . 33
FRONT DOOR REFLECTOR . . . . . . . . . . . . . . . 34
FRONT DOOR SILL PLATE . . . . . . . . . . . . . . . . 34
FRONT DOOR TRIM PANEL . . . . . . . . . . . . . . . . 34
FRONT DOOR WEATHER-STRIP . . . . . . . . . . . . 36
FRONT DOOR WINDOW CRANK . . . . . . . . . . . . 36
FRONT DOOR WINDOW REGULATOR . . . . . . . 36
FRONT DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . 27
FRONT SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
FRONT WHEELHOUSE SPLASH SHIELD . . . . . 37
FUEL FILL DOOR BLOCKER LATCH STRIKER . . 38
FUEL FILL DOOR BLOCKER LATCH . . . . . . . . . 38
FUEL FILL DOOR BLOCKER LOCKOUT LINK . . 38
FUEL FILLER HOUSING WITH BLOCKER
LATCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
GRILLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
HEADLINING . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
HOOD HINGE . . . . . . . . . . . . . . . . . . . . . . . . . . 41
HOOD LATCH STRIKER . . . . . . . . . . . . . . . . . . . 42
HOOD LATCH . . . . . . . . . . . . . . . . . . . . . . . . . . 41
HOOD RELEASE CABLE . . . . . . . . . . . . . . . . . . 42
HOOD RELEASE HANDLE . . . . . . . . . . . . . . . . . 42
HOOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
JACK STORAGE COVER . . . . . . . . . . . . . . . . . . 43
LEFT D-PILLAR TRIM PANEL . . . . . . . . . . . . . . . 43
LEFT QUARTER TRIM PANEL . . . . . . . . . . . . . . 44
LIFTGATE CHMSL ACCESS PANEL . . . . . . . . . . 47
LIFTGATE HINGE . . . . . . . . . . . . . . . . . . . . . . . . 47
LIFTGATE LATCH STRIKER . . . . . . . . . . . . . . . . 47
LIFTGATE LATCH . . . . . . . . . . . . . . . . . . . . . . . . 47
LIFTGATE LOCK CYLINDER . . . . . . . . . . . . . . . 48
LIFTGATE OUTSIDE HANDLE . . . . . . . . . . . . . . 48
LIFTGATE PROP ASSEMBLY . . . . . . . . . . . . . . . 49
LIFTGATE SILL PLATE . . . . . . . . . . . . . . . . . . . . 49
LIFTGATE STABILIZER WEDGE STRIKER . . . . . 49
LIFTGATE STABILIZER WEDGE . . . . . . . . . . . . . 49
LIFTGATE TRIM PANEL . . . . . . . . . . . . . . . . . . . 50
LIFTGATE UPPER FRAME MOLDING . . . . . . . . 50
LIFTGATE UPPER FRAME SIDE MOLDINGS . . . 51
LIFTGATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
LOWER B-PILLAR TRIM COVER . . . . . . . . . . . . 51
LUGGAGE RACK CROSSBAR . . . . . . . . . . . . . . 51
LUGGAGE RACK RISER COVER . . . . . . . . . . . . 52
LUGGAGE RACK SIDE RAIL . . . . . . . . . . . . . . . 52
OVERHEAD GRAB-HANDLES . . . . . . . . . . . . . . 52
QUARTER GLASS . . . . . . . . . . . . . . . . . . . . . . . 52
QUARTER TRIM BOLSTER . . . . . . . . . . . . . . . . 53
RADIATOR CLOSURE PANEL CROSSMEMBER . 53
RAIL LAMP MODULE . . . . . . . . . . . . . . . . . . . . . 54
REAR HEADER TRIM . . . . . . . . . . . . . . . . . . . . . 55
REAR HVAC LOUVER AND BEZEL . . . . . . . . . . 55
RIGHT D-PILLAR TRIM PANEL . . . . . . . . . . . . . . 55
RIGHT QUARTER TRIM PANEL . . . . . . . . . . . . . 56
ROOF APERTURE (RAP) MOLDING . . . . . . . . . . 57
SEAT BELT BUCKLE FIRST REAR QUAD
BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
SEAT BELT BUCKLE FIRST REAR TWO
PASSENGER BENCH . . . . . . . . . . . . . . . . . . . 58
SEAT BELT BUCKLE SECOND REAR THREE
PASSENGER BENCH . . . . . . . . . . . . . . . . . . . 59
SEAT BELT BUCKLE FRONT INBOARD . . . . . 57
SEAT BELT FIRST REAR ANCHOR BRACKET
LWB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
SEAT BELT FIRST REAR OUTBOARD LWB
FOUR DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . 60
SEAT BELT FIRST REAR OUTBOARD SWB
FOUR DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . 60
SEAT BELT LEFT FIRST REAR OUTBOARD
LWB THREE DOOR . . . . . . . . . . . . . . . . . . . . . 61
SEAT BELT LEFT FIRST REAR OUTBOARD
SWB THREE DOOR . . . . . . . . . . . . . . . . . . . . 61
SEAT BELT SECOND REAR OUTBOARD
SWB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
SEAT BELT SECOND RIGHT REAR OUTBOARD
LWB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
SEAT BELT OUTBOARD FRONT . . . . . . . . . . . 59
SECOND RIGHT REAR OUTBOARD SEAT BELT
LWB W/REAR HVAC . . . . . . . . . . . . . . . . . . . 62
23 - 22 BODY NS
SHOULDER BELT HEIGHT ADJUSTER KNOB . . 64
SHOULDER BELT HEIGHT ADJUSTER B OR
C-PILLAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
SIDE VIEW MIRROR . . . . . . . . . . . . . . . . . . . . . 64
SLIDING DOOR CENTER HINGE . . . . . . . . . . . . 66
SLIDING DOOR CENTER STOP TRIM COVER . . 66
SLIDING DOOR CENTER STRIKER ASSEMBLY . 67
SLIDING DOOR HOLD OPEN LATCH STRIKER . 67
SLIDING DOOR HOLD OPEN LATCH . . . . . . . . . 67
SLIDING DOOR INSIDE LATCH HANDLE
BELLCRANK . . . . . . . . . . . . . . . . . . . . . . . . . . 68
SLIDING DOOR INSIDE LATCH HANDLE . . . . . . 68
SLIDING DOOR INSIDE LATCH RELEASE
MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . 69
SLIDING DOOR LATCH STRIKER . . . . . . . . . . . 69
SLIDING DOOR LATCH/LOCK CONTROL . . . . . 70
SLIDING DOOR LOWER ROLLER ARM
BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
SLIDING DOOR LOWER ROLLER ARM . . . . . . . 71
SLIDING DOOR OUTSIDE LATCH RELEASE
HANDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
SLIDING DOOR REAR LATCH . . . . . . . . . . . . . . 73
SLIDING DOOR SILL PLATE . . . . . . . . . . . . . . . 73
SLIDING DOOR STABILIZER SOCKET . . . . . . . . 74
SLIDING DOOR STABILIZER . . . . . . . . . . . . . . . 73
SLIDING DOOR STOP BUMPER . . . . . . . . . . . . 74
SLIDING DOOR TRIM PANEL . . . . . . . . . . . . . . . 74
SLIDING DOOR UPPER ROLLER . . . . . . . . . . . . 75
SLIDING DOOR WEATHER-STRIP . . . . . . . . . . . 75
SLIDING DOOR . . . . . . . . . . . . . . . . . . . . . . . . . 64
STICK-ON BODY SIDE MOLDING . . . . . . . . . . . 75
SUN VISOR SUPPORT . . . . . . . . . . . . . . . . . . . 78
SUN VISOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
UPPER B-PILLAR TRIM COVER . . . . . . . . . . . . . 78
UPPER C-PILLAR TRIM . . . . . . . . . . . . . . . . . . . 80
ADJUSTMENTS
SLIDING DOOR ADJUSTMENTS . . . . . . . . . . . . 80
WATER LEAKS
Water l eaks can be caused by poor seal i ng,
i mproper body component al i gnment, body seam
porosi ty, mi ssi ng pl ugs, or bl ocked drai n hol es. Cen-
tri fugal and gravi tati onal force can cause water to
dri p from a l ocati on away from the actual l eak poi nt,
maki ng l eak detecti on di ffi cul t. Al l body seal i ng
poi nts shoul d be water ti ght i n normal wet-dri vi ng
condi ti ons. Water fl owi ng downward from the front of
the vehi cl e shoul d not enter the passenger or l uggage
compartment. Movi ng seal i ng surfaces wi l l not
al ways seal water ti ght under al l condi ti ons. At
ti mes, si de gl ass or door seal s wi l l al l ow water to
enter the passenger compartment duri ng hi gh pres-
sure washi ng or hard dri vi ng rai n (severe) condi -
ti ons. Overcompensati ng on door or gl ass
adjustments to stop a water l eak that occurs under
severe condi ti ons can cause premature seal wear and
excessi ve cl osi ng or l atchi ng effort. After compl eti ng
a repai r, water-test vehi cl e to veri fy l eak has stopped
before returni ng vehi cl e to use.
VISUAL INSPECTION BEFORE WATER LEAK
TESTS
Veri fy that fl oor and body pl ugs are i n pl ace, body
drai ns are cl ear, and body components are properl y
al i gned and seal ed. I f component al i gnment or seal -
i ng i s necessary, refer to the appropri ate secti on of
thi s group for proper procedures.
WATER LEAK TESTS
WARNING: DO NOT USE ELECTRIC SHOP LIGHTS
OR TOOLS IN WATER TEST AREA. PERSONAL
INJURY CAN RESULT.
When the condi ti ons causi ng a water l eak have
been determi ned, si mul ate the condi ti ons as cl osel y
as possi bl e.
I f a l eak occurs wi th the vehi cl e parked i n a
steady l i ght rai n, fl ood the l eak area wi th an open-
ended garden hose.
I f a l eak occurs whi l e dri vi ng at hi ghway speeds
i n a steady rai n, test the l eak area wi th a reasonabl e
vel oci ty stream or fan spray of water. Di rect the
spray i n a di recti on comparabl e to actual condi ti ons.
I f a l eak occurs when the vehi cl e i s parked on an
i ncl i ne, hoi st the end or si de of the vehi cl e to si mu-
l ate thi s condi ti on. Thi s method can be used when
the l eak occurs when the vehi cl e accel erates, stops or
turns. I f the l eak occurs on accel erati on, hoi st the
front of the vehi cl e. I f the l eak occurs when braki ng,
hoi st the back of the vehi cl e. I f the l eak occurs on l eft
turns, hoi st the l eft si de of the vehi cl e. I f the l eak
occurs on ri ght turns, hoi st the ri ght si de of the vehi -
cl e. For hoi sti ng recommendati ons refer to Group 0,
Lubri cati on and Mai ntenance, General I nformati on
secti on.
WATER LEAK DETECTION
To detect a water l eak poi nt-of-entry, do a water
test and watch for water tracks or dropl ets formi ng
on the i nsi de of the vehi cl e. I f necessary, remove i nte-
ri or tri m covers or panel s to gai n vi sual access to the
l eak area. I f the hose cannot be posi ti oned wi thout
bei ng hel d, have someone hel p do the water test.
NS BODY 23 - 23
Some water l eaks must be tested for a consi derabl e
l ength of ti me to become apparent. When a l eak
appears, fi nd the hi ghest poi nt of the water track or
drop. The hi ghest poi nt usual l y wi l l show the poi nt of
entry. After l eak poi nt has been found, repai r the
l eak and water test to veri fy that the l eak has
stopped.
Locati ng the entry poi nt of water that i s l eaki ng
i nto a cavi ty between panel s can be di ffi cul t. The
trapped water may spl ash or run from the cavi ty,
often at a di stance from the entry poi nt. Most water
l eaks of thi s type become apparent after accel erati ng,
stoppi ng, turni ng, or when on an i ncl i ne.
MIRROR INSPECTION METHOD
When a l eak poi nt area i s vi sual l y obstructed, use
a sui tabl e mi rror to gai n vi sual access. A mi rror can
al so be used to defl ect l i ght to a l i mi ted-access area
to assi st i n l ocati ng a l eak poi nt.
BRIGHT LIGHT LEAK TEST METHOD
Some water l eaks i n the l uggage compartment can
be detected wi thout water testi ng. Posi ti on the vehi -
cl e i n a bri ghtl y l i t area. From i nsi de the darkened
l uggage compartment i nspect around seal s and body
seams. I f necessary, have a hel per di rect a drop l i ght
over the suspected l eak areas around the l uggage
compartment. I f l i ght i s vi si bl e through a normal l y
seal ed l ocati on, water coul d enter through the open-
i ng.
PRESSURIZED LEAK TEST METHOD
When a water l eak i nto the passenger compart-
ment cannot be detected by water testi ng, pressuri ze
the passenger compartment and soap test exteri or of
the vehi cl e. To pressuri ze the passenger compart-
ment, cl ose al l doors and wi ndows, start engi ne, and
set heater control to hi gh bl ower i n HEAT posi ti on. I f
engi ne can not be started, connect a charger to the
battery to ensure adequate vol tage to the bl ower.
Wi th i nteri or pressuri zed, appl y di sh detergent sol u-
ti on to suspected l eak area on the exteri or of the
vehi cl e. Appl y detergent sol uti on wi th spray devi ce or
soft bri stl e brush. I f soap bubbl es occur at a body
seam, joi nt, seal or gasket, the l eak entry poi nt coul d
be at that l ocati on.
WIND NOISE
Wi nd noi se i s the resul t of most ai r l eaks. Ai r l eaks
can be caused by poor seal i ng, i mproper body compo-
nent al i gnment, body seam porosi ty, or mi ssi ng pl ugs
i n the engi ne compartment or door hi nge pi l l ar areas.
Al l body seal i ng poi nts shoul d be ai rti ght i n normal
dri vi ng condi ti ons. Movi ng seal i ng surfaces wi l l not
al ways seal ai rti ght under al l condi ti ons. At ti mes,
si de gl ass or door seal s wi l l al l ow wi nd noi se to be
noti ced i n the passenger compartment duri ng hi gh
crosswi nds. Over compensati ng on door or gl ass
adjustments to stop wi nd noi se that occurs under
severe condi ti ons can cause premature seal wear and
excessi ve cl osi ng or l atchi ng effort. After a repai r pro-
cedure has been performed, test vehi cl e to veri fy
noi se has stopped before returni ng vehi cl e to use.
Wi nd noi se can al so be caused by i mproperl y fi tted
exteri or mol di ngs or body ornamentati on. Loose
mol di ngs can fl utter, creati ng a buzzi ng or chatteri ng
noi se. An open cavi ty or protrudi ng edge can create a
whi stl i ng or howl i ng noi se. I nspect the exteri or of the
vehi cl e to veri fy that these condi ti ons do not exi st.
VISUAL INSPECTION BEFORE TESTS
Veri fy that fl oor and body pl ugs are i n pl ace and
body components are al i gned and seal ed. I f component
al i gnment or seal i ng i s necessary, refer to the appro-
pri ate secti on of thi s group for proper procedures.
ROAD TESTING WIND NOISE
(1) Dri ve the vehi cl e to veri fy the general l ocati on
of the wi nd noi se.
(2) Appl y 50 mm (2 i n.) maski ng tape i n 150 mm
(6 i n.) l engths al ong weatherstri ps, wel d seams or
mol di ngs. After each l ength i s appl i ed, dri ve the vehi -
cl e. I f noi se goes away after a pi ece of tape i s appl i ed,
remove tape, l ocate, and repai r defect.
POSSIBLE CAUSE OF WIND NOISE
Mol di ngs standi ng away from body surface can
catch wi nd and whi stl e.
Gaps i n seal ed areas behi nd overhangi ng body
fl anges can cause wi nd-rushi ng sounds.
Mi sal i gned movabl e components.
Mi ssi ng or i mproperl y i nstal l ed pl ugs i n pi l l ars.
Wel d burn through hol es.
SERVICE PROCEDURES
HEAT STAKING
(1) Remove tri m panel .
(2) Bend or move the tri m panel components at
the heat staked joi nts. Observe the heat staked l oca-
ti ons and/or component seams for l ooseness.
(3) Heat stake the components.
(a) I f the heat staked or component seam l oca-
ti on i s l oose, hol d the two components ti ghtl y
together and usi ng a sol deri ng gun wi th a fl at ti p,
mel t the materi al securi ng the components
together. Do not over heat the affected area, dam-
age to the exteri or of the tri m panel may occur.
(b) I f the heat staked materi al i s broken or mi ss-
i ng, use a hot gl ue gun to appl y new materi al to
the area to be repai red. The panel s that are bei ng
heat staked must be hel d together whi l e the appl y-
i ng the gl ue. Once the new materi al i s i n pl ace, i t
23 - 24 BODY NS
may be necessary to use a sol deri ng gun to mel t
the newl y appl i ed materi al . Do not over heat the
affected area, damage to the exteri or of the tri m
panel may occur.
(4) Al l ow the repai red area to cool and veri fy the
repai r.
(5) I nstal l tri m panel .
A-PILLAR LOWER EXTENSION TRIM
REMOVAL
(1) Remove i nstrument panel si de cover.
(2) Remove screw hol di ng A-pi l l ar extensi on to
door hi nge pi l l ar.
(3) Remove A-pi l l ar extensi on tri m from vehi cl e
(Fi g. 1).
INSTALLATION
(1) Pl ace A-pi l l ar extensi on tri m i n posi ti on on
vehi cl e.
(2) I nstal l screw to hol d A-pi l l ar extensi on to door
hi nge pi l l ar.
(3) I nstal l i nstrument panel si de cover.
A-PILLAR TRIM PANEL
REMOVAL
(1) Di sengage hi dden cl i ps hol di ng A-pi l l ar tri m
panel to A-pi l l ar (Fi g. 2).
(2) Remove A-pi l l ar tri m from vehi cl e.
INSTALLATION
(1) Posi ti on foot on A-pi l l ar tri m panel i nto i nstru-
ment panel top cover channel .
(2) Posi ti on A-pi l l ar tri m i n vehi cl e.
(3) Al i gn l ocator pi ns.
(4) Engage hi dden cl i ps.
COWL COVER
WARNING: No fingers or tools should be put under
the cowl cover while the wiper motor is operating.
REMOVAL
(1) Remove wi per arms. Refer to Group 8K, Wi nd-
shi el d Wi pers and Washers for proper procedures.
(2) Remove screws hol di ng l ower area of cowl cover
to wi per modul e (Fi g. 3).
(3) Di sengage quarter turn fasteners hol di ng outer
ends of cowl cover to wi per modul e.
(5) Remove wi ng nuts hol di ng front of cowl cover
to wi per modul e.
(6) Cl ose hood. Do not l atch. Remove outboard
screws. (Fi g. 4).
(7) Li ft cowl cover upward enough to gai n access to
ri ght washer hose.
(8) Di sconnect washer hose from ri ght washer nozzl e.
(9) Cl ose hood. Do not l atch.
(10) Remove cowl cover from vehi cl e.
INSTALLATION
COWL TRIM
REMOVAL
(1) Remove door si l l pl ate.
(2) Di sengage hi dden cl i ps hol di ng cowl tri m to
cowl panel (Fi g. 5).
(3) Remove cowl tri m from vehi cl e.
Fig. 1 A-pillar Lower Extension Trim
Fig. 2 A-pillar Trim
NS BODY 23 - 25
INSTALLATION
(1) Pl ace cowl tri m si l l pl ate i n posi ti on on vehi cl e.
(2) Engage hi dden cl i ps to hol d cowl tri m to cowl
panel .
(3) I nstal l door si l l pl ate.
FLOOR CARPET
REMOVAL
(1) Remove front seats.
(2) Remove front center consol e.
(3) Remove fi rst rear seat.
(4) Remove second rear seat.
(5) Remove front cowl panel s and si l l pl ates.
(6) Remove sl i di ng door si l l pl ates.
(7) Remove rear door si l l pl ate.
(8) Remove l ower B-pi l l ar tri m covers.
(9) Remove D-pi l l ar tri m covers.
(10) Remove Quarter tri m panel s.
(11) Remove fl oor escutcheons (Fi g. 6).
(12) Remove push-i n fasteners hol di ng carpet to
fl oor i n front seat area.
(13) Rol l carpet from under i nstrument panel to
center of sl i di ng door.
(14) Rol l carpet forward away from rear door open-
i ng.
(15) Extract carpet through sl i di ng door openi ng
(Fi g. 7).
INSTALLATION
(1) I nsert carpet through sl i di ng door openi ng.
(2) Rol l carpet rearward toward rear door openi ng.
(3) Rol l carpet under i nstrument panel .
(4) I nstal l push-i n fasteners through carpet and
grommet i nto fl oor to hol d carpet to fl oor i n front
seat area.
Fig. 3 Cowl Cover
Fig. 4 Cowl Cover Retainers
Fig. 5 Cowl Trim
Fig. 6 Seat Escutcheons
23 - 26 BODY NS
CAUTION: Ensure that the correct fasteners are
installed in the proper locations. Damage to the fuel
tank may result.
(5) I nstal l fl oor escutcheons.
(6) I nstal l Quarter tri m panel s.
(7) I nstal l D-pi l l ar tri m covers.
(8) I nstal l l ower B-pi l l ar tri m covers.
(9) I nstal l rear door si l l pl ate.
(10) I nstal l sl i di ng door si l l pl ates.
(11) I nstal l front cowl panel s and si l l pl ates.
(12) I nstal l second rear seat.
(13) I nstal l fi rst rear seat.
(14) I nstal l front center consol e.
(15) I nstal l front seats.
FRONT DOOR
CAUTION: If the hinge pin must be removed from
the hinge, do not reuse the original pin. The struc-
tural integrity of the hinge would be reduced. Verify
availability prior to proceeding if hinge pins are to
be removed.
NOTE: The retaining clips used on the door hinge
pins are not to be re-used. Verify availability prior to
proceeding if clips are to be removed.
REMOVAL
(1) Open front door.
(2) Remove front wheel house spl ash shi el d.
(3) Di sengage cl i ps hol di ng door harness wi re con-
nector to i nner fender brace.
(4) Di sconnect posi ti ve l ock sl i de on the si de of the
wi re connectors (Fi g. 8).
(5) Depress l ock tab hol di ng wi re connector hal ves
together.
(6) Di sconnect door harness from body wi ri ng har-
ness.
(7) Remove bol ts hol di ng door check strap to A-pi l -
l ar (Fi g. 9).
(8) Support door on sui tabl e l i fti ng devi ce.
(9) Remove bol ts hol di ng l ower hi nge to door end
frame (Fi g. 10).
(10) Steady door on l i fti ng devi ce and remove bol ts
hol di ng upper hi nge to door end frame.
(11) Remove door from vehi cl e.
INSTALLATION
NOTE: If new hinge pins are to be used, verify that
the knurling on the hinge pin is aligned with the
knurling on in the door hinge prior to driving in the
pin. Also, verify that the hinge pin is fully seated to
the door hinge and a new retaining clip is installed.
(2) Posi ti on door to vehi cl e.
(3) Steady door on l i fti ng devi ce and i nstal l bol ts
to hol d upper hi nge to door end frame.
(4) I nstal l bol ts to hol d door check strap to A-pi l -
l ar.
(5) I nstal l bol ts to hol d l ower hi nge to door end
frame. Al i gn door to achi eve equal spaci ng to sur-
roundi ng body panel s. Panel s shoul d be fl ush across
al l gaps.
Fig. 7 Floor Carpet
Fig. 8 Front Door Wire Connectors
NS BODY 23 - 27
(6) Connect door harness i nto body wi ri ng harness.
(7) Connect posi ti ve l ock sl i de on the si de of the
wi re connectors.
(8) Connect cl i ps to hol d door harness wi re connec-
tor to i nner fender brace.
(9) I nstal l front wheel house spl ash shi el d.
(10) Veri fy door operati on and al i gnment. Adjust
as necessary.
FRONT DOOR APPLIQUE
REMOVAL
(1) Rol l door gl ass down.
(2) Remove outer door bel t mol di ng.
(3) Di sengage cl i ps hol di ng front edge of appl i que
to door frame.
(4) Remove appl i que from vehi cl e (Fi g. 11).
INSTALLATION
(1) Posi ti on appl i que on vehi cl e.
(2) Hook rear edge of appl i que over rear edge of
door frame and seat appl i que bottom edge on sheet
metal .
(3) Engage cl i ps to hol d front edge of appl i que to
door frame.
(4) I nstal l outer door bel t mol di ng.
FRONT DOOR CHECK STRAP
REMOVAL
(1) Remove front door tri m panel .
(2) Remove door speaker, i f equi pped.
(3) Remove bol ts attachi ng door check strap to
A-pi l l ar (Fi g. 9).
(4) Remove nuts attachi ng check strap to door end
frame (Fi g. 12).
(5) Remove check strap from door through speaker
hol e.
Fig. 9 Front Door Hinge Pin Removal
Fig. 10 Front Door Hinge Bolt Removal
Fig. 11 Front Door Applique
23 - 28 BODY NS
INSTALLATION
(1) Posi ti on check strap on door through speaker
hol e.
(2) I nstal l nuts to attach check strap to door end
frame.
(3) I nstal l bol ts to attach check strap to A-pi l l ar.
(4) I nstal l door speaker, i f equi pped.
(5) I nstal l front door tri m panel .
FRONT DOOR FRAME CLOSEOUT MOLDINGS
REMOVAL A-PILLAR, HEADER, OR B-PILLAR
(2) Usi ng a hook tool , pul l front door frame cl ose-
out mol di ng from wi ndow frame channel (Fi g. 13).
(3) Remove cl oseout mol di ng from vehi cl e.
INSTALLATION A-PILLAR, HEADER, OR
B-PILLAR
(1) Posi ti on cl oseout mol di ng i n wi ndow frame.
(2) I nsert cl oseout mol di ng i nto wi ndow frame
channel starti ng at the corners and worki ng i nward.
(3) Veri fy door gl ass operati on.
FRONT DOOR GLASS
REMOVAL
(1) Remove door tri m panel and water shi el d.
(2) Remove i nner bel t mol di ng.
(3) Remove outer bel t mol di ng.
(4) Remove radi o speaker, i f equi pped.
(5) Posi ti on gl ass to gai n access to front and rear
regul ator l i ft pl ates through front and rear access
hol es i n door panel .
(6) Remove cl i ps hol di ng door gl ass to regul ator
l i ft pl ates (Fi g. 14).
(7) Remove gl ass from regul ator l i ft pl ates.
(8) Di sengage gl ass from gl ass run weather-stri p.
(9) I nsert front of gl ass between gl ass run channel
and outer door panel .
(10) Li ft gl ass upward and out of exteri or si de of
the openi ng at top of door (Fi g. 15).
(11) Remove gl ass from vehi cl e.
INSTALLATION
(1) I nstal l cl i ps that hol d door gl ass to regul ator
l i ft pl ates (Fi g. 14).
(2) Pl ace gl ass i n wi ndow openi ng wi th front
i nserted between run channel and outer door panel
(Fi g. 15).
Fig. 12 Front Door Check Strap
Fig. 13 Front Door Frame Closeout Moldings
Fig. 14 Front Door Glass Clips
NS BODY 23 - 29
(3) Lower gl ass downward i nto door.
(4) I nsert ends of gl ass i nto gl ass run weather-
stri p channel s at front and rear of door.
(5) Pl ace gl ass i n posi ti on on regul ator l i ft pl ates.
(6) Snap gl ass mounti ng studs i nto cl i ps on regu-
l ator l i ft pl ates.
(7) I nstal l radi o speaker, i f equi pped.
(8) I nstal l outer bel t mol di ng.
(9) I nstal l i nner bel t mol di ng.
(10) Veri fy door gl ass operati on and fi t.
(11) I nstal l water shi el d and door tri m panel .
FRONT DOOR GLASS RUN WEATHER-STRIP
REMOVAL
(1) Remove door frame cl oseout mol di ngs.
(2) Pul l weather-stri p from gl ass run channel at
rear of door frame, worki ng from the bottom to the
top.
(3) Di sengage cl i p hol di ng weather-stri p to door
frame.
(4) Pul l weather-stri p from l i p al ong top of door
frame (Fi g. 16).
(5) Remove door tri m panel .
(6) Remove door speaker, i f equi pped.
(7) Remove watershed as necessary to gai n access
to screw hol di ng front l ower corner of gl ass run
weather-stri p to i nner door panel .
(8) Remove screw hol di ng gl ass run weather-stri p
to i nner door panel .
(9) Remove i nner bel t weather-stri p.
(10) Pul l weather-stri p from front gl ass run chan-
nel .
(11) Remove gl ass run weather-stri p from vehi cl e.
INSTALLATION
(1) Posi ti on gl ass run weather-stri p on vehi cl e.
(2) Push weather-stri p i nto front gl ass run chan-
nel .
(3) I nstal l screw to hol d gl ass run weather-stri p to
i nner door panel .
(4) I nstal l i nner bel t weather-stri p.
(5) I nstal l watershed.
(6) Push weather-stri p groove onto l i p al ong top of
door frame.
(7) Engage cl i p i nto sl ot i n door frame.
(8) Push weather-stri p i nto channel at rear of door
frame, worki ng from the top to bottom.
(9) I nstal l door frame cl oseout mol di ngs.
(10) I nstal l door speaker, i f equi pped.
(11) I nstal l door tri m panel .
FRONT DOOR HINGE
CAUTION: If the hinge pin must be removed from
the hinge, do not reuse the original pin. The struc-
tural integrity of the hinge would be reduced.
Fig. 15 Front Door Glass
Fig. 16 Front Door Glass Run Weather-strip
23 - 30 BODY NS
NOTE: If both hinges on one door are to be
replaced, remove and install one hinge completely
prior to beginning the second hinge.
REMOVAL
(1) Rel ease front door l atch and open door.
(3) Remove bol ts hol di ng front door to door hi nge.
(4) Remove bol ts hol di ng hi nge to pi l l ar.
(5) Remove door hi nge from vehi cl e.
INSTALLATION
CAUTION: When installing a new hinge, make sure
that the head of each hinge pin is fully seated into
the door hinge. Also, remove the plastic shipping
clip and replace it with the correct metal retaining
clip once the hinge pin is seated.
(1) Pai nt hi nge pri or to i nstal l ati on, i f necessary.
(2) Posi ti on door hi nge on vehi cl e.
(3) I nstal l bol ts to hol d hi nge to pi l l ar.
(4) I nstal l bol ts to hol d front door to door hi nge.
(5) Al i gn door to achi eve equal spaci ng to sur-
roundi ng body panel s. Panel s shoul d be fl ush across
al l gaps.
(6) Veri fy door al i gnment and operati on. Adjust as
necessary.
FRONT DOOR INNER BELT MOLDING
REMOVAL
(2) Peel upper corner seal s away form i nner bel t
mol di ng to cl ear removal path.
(3) Pul l i nner bel t mol di ng upward to di sengage
retai ni ng channel i n bottom of mol di ng from door
panel fl ange (Fi g. 17).
(4) Remove i nner bel t mol di ng from vehi cl e.
INSTALLATION
(1) Pl ace i nner bel t mol di ng i n posi ti on on door.
(2) Push i nner bel t mol di ng downward to engage
retai ni ng channel onto door panel fl ange.
(3) I nstal l upper corner seal s i n proper l ocati on.
FRONT DOOR LATCH
REMOVAL
(1) Remove front door tri m panel .
access to the outsi de door handl e.
(3) Rol l door gl ass up.
(4) Through access hol e at rear of i nner door
panel , di sengage wi re connector from power door l ock
motor, i f equi pped.
(5) Di sengage cl i ps hol di ng l i nkage to door l atch.
(6) Remove l i nkages from door l atch.
(7) Remove screws hol di ng door l atch to door end
frame (Fi g. 18).
(8) Remove door l atch from door.
Fig. 17 Front Door Inner Belt Molding
Fig. 18 Front Door Latch
NS BODY 23 - 31
INSTALLATION
NOTE: The screws attaching the door latch to the
door end frame have nylon patches on the threads.
All screws must be replaced when the latch has
been removed.
(1) Pl ace door l atch i n posi ti on on door end frame.
(2) I nstal l screws to hol d door l atch to door end
frame.
(3) I nsert l i nkage i nto door l atch.
(4) Engage cl i ps to hol d l i nkage to door l atch.
(5) Connect wi re connector i nto power door l ock
(6) I nsert a hex wrench through the el ongated hol e
l ocated i n the door shut face above the l atch.
(7) Loosen al l en head screw.
(8) Pul l outward on the outsi de door handl e and
rel ease.
(9) Ti ghten al l en head screw.
(10) Veri fy door l atch and power door l ock opera-
ti on.
(11) I nstal l water shi el d and front door tri m panel .
FRONT DOOR LATCH STRIKER
REMOVAL
(1) Mark outl i ne of door stri ker on B-pi l l ar to ai d
i n i nstal l ati on.
(2) Remove screws hol di ng door l atch stri ker to
(3) Remove door l atch stri ker from vehi cl e.
(4) Retri eve any shi ms found between l atch stri ker
and B-pi l l ar.
INSTALLATION
(1) Posi ti on l atch stri ker and any shi ms retri eved
on vehi cl e.
(2) Loosel y i nstal l screws to hol d l atch stri ker to
B-pi l l ar.
(3) Al i gn l atch stri ker to outl i ne on B-pi l l ar made
previ ousl y.
(4) Ti ghten al l fasteners.
(5) Veri fy door fi t and operati on. Adjust l atch
stri ker as necessary.
FRONT DOOR LOCK CYLINDER
REMOVAL
as necessary to gai n access to the outsi de door han-
dl e.
panel , di sconnect vehi cl e theft Securi ty System
(VTSS) swi tch connector from door harness, i f
equi pped.
(4) Di sengage push-i n fasteners hol di ng VTSS
swi tch harness to i nner door rei nforcement bar, i f
equi pped.
(5) Di sengage cl i p hol di ng door l atch l i nkage to
door l atch.
(6) Remove l atch l i nkage from l atch.
(7) Di sengage cl i p hol di ng door l ock l i nkage to
door l atch.
(8) Remove l ock l i nkage from l atch.
(9) Remove nuts hol di ng outsi de door handl e to
door outer panel (Fi g. 23).
(10) Remove outsi de door handl e from vehi cl e.
(11) Di sengage cl i p hol di ng l ock cyl i nder i nto out-
si de handl e (Fi g. 20).
(12) Pul l l ock cyl i nder from door handl e.
Fig. 19 Door Latch Striker
Fig. 20 Remove Front Door Lock Cylinder
23 - 32 BODY NS
INSTALLATION
(1) Engage cl i p i nto outsi de handl e to hol d l ock
cyl i nder.
(2) Wi th l i nk arm toward rear of vehi cl e, push l ock
cyl i nder i nto door handl e unti l cl i p snaps i nto pl ace
(Fi g. 21).
(3) I nsert l ock l i nkage i nto door l atch.
(4) Engage cl i p to hol d door l ock l i nkage to l atch.
(5) I nsert l atch l i nkage i nto door l atch.
(6) Engage cl i p to hol d door l atch l i nkage to l atch.
(7) I nstal l push-i n fasteners to hol d VTSS swi tch
harness to i nner door rei nforcement bar, i f equi pped.
(8) Connect VTSS swi tch connector i nto door har-
ness, i f equi pped.
(9) Veri fy door l atch operati on.
FRONT DOOR OUTER BELT MOLDING
REMOVAL
(3) Usi ng a hook tool , di sengage i nterl ocki ng l i p at
the base of the i nward edge of the bel t mol di ng (Fi g.
22).
(4) Remove bel t mol di ng from door.
INSTALLATION
(1) Pl ace bel t mol di ng i n posi ti on on door.
(2) Engage i nterl ocki ng l i p at the base of the
i nward edge of the bel t mol di ng on door panel .
FRONT DOOR OUTSIDE HANDLE
REMOVAL
as necessary to gai n access to the outsi de door han-
dl e.
panel , di sconnect vehi cl e theft Securi ty System
(VTSS) swi tch connector from door harness, i f
equi pped.
(4) Di sengage push-i n fasteners hol di ng VTSS
swi tch harness to i nner door rei nforcement bar, i f
equi pped.
(5) Di sengage cl i p hol di ng door l atch l i nkage to
door l atch.
(6) Remove l atch l i nkage from l atch.
(7) Di sengage cl i p hol di ng door l ock l i nkage to
door l atch.
(8) Remove l ock l i nkage from l atch.
door outer panel (Fi g. 23).
Fig. 21 Install Front Door Lock Cylinder
Fig. 22 Front Door Outer Belt Molding
Fig. 23 Front Door Outside Handle
NS BODY 23 - 33
INSTALLATION
I f outsi de door handl e repl acement i s necessary,
transfer l ock cyl i nder from the ori gi nal handl e to the
new one.
(1) Pl ace outsi de door handl e i n posi ti on on vehi -
cl e.
(2) I nstal l nuts to hol d outsi de door handl e to door
outer panel (Fi g. 23).
(3) I nsert l ock l i nkage i nto door l atch.
(4) Engage cl i p to hol d door l ock l i nkage to l atch.
(5) I nsert l atch l i nkage i nto door l atch.
(6) Engage cl i p to hol d door l atch l i nkage to l atch.
(7) I nstal l push-i n fasteners to hol d VTSS swi tch
harness to i nner door rei nforcement bar, i f equi pped.
(8) Connect VTSS swi tch connector i nto door har-
ness, i f equi pped.
(9) Veri fy door l atch operati on.
FRONT DOOR REFLECTOR
REMOVAL
(1) I nsert smal l , fl at bl aded pry tool between outer
edge of door refl ector and HVAC outl et vent.
(2) Pry outward on outer edge of refl ector.
(3) Remove refl ector from vehi cl e (Fi g. 24).
INSTALLATION
(1) Posi ti on refl ector on vehi cl e.
(2) I nsert i nner edge of refl ector i nto sl ot i n HVAC
outl et vent.
(3) Snap outer edge of refl ector i nto sl ot i n HVAC
outl et vent.
FRONT DOOR SILL PLATE
REMOVAL
(1) Usi ng tri m sti ck (C-4755), di sengage hi dden
cl i ps hol di ng door si l l pl ate from door si l l .
(2) Remove si l l pl ate from vehi cl e (Fi g. 25).
INSTALLATION
(1) Pl ace si l l pl ate i n posi ti on on vehi cl e.
(2) Al i gn l ocati ng pi ns on backsi de of tri m pl ate to
mati ng hol es i n door si l l .
(3) Engage hi dden cl i ps to hol d door si l l pl ate to
door si l l .
FRONT DOOR TRIM PANEL
REMOVAL
(1) Usi ng a tri m sti ck (C-4755), pry courtesy l amp
from door tri m.
(2) Di sconnect wi re connector from courtesy l amp.
(3) I f equi pped, remove screws attachi ng door
assi st handl e to i nner door panel .
(4) I f equi pped, remove screw attachi ng door pul l
cup to i nner door panel .
(5) I f equi pped, remove screws attachi ng tri m
panel to door from bel ow map pocket.
(6) I f equi pped, remove wi ndow crank.
(7) Usi ng a tri m sti ck, remove screw cover from
swi tch panel .
(8) Remove screws attachi ng swi tch panel to door
tri m.
(9) Remove power accessary swi tch from door tri m
(Fi g. 26).
(10) Di sconnect power swi tch from wi re connector.
(11) I f equi pped, usi ng a smal l , fl at bl aded pry
tool , remove memory seat/mi rror swi tch and di scon-
nect wi re connector (Fi g. 27).
(12) I f equi pped, remove screw hol di ng door tri m
to door panel from behi nd i nsi de l atch rel ease han-
dl e.
(13) Di sengage cl i ps attachi ng door tri m to door
frame around peri meter of panel (Fi g. 28).
(14) Li ft tri m panel upward to di sengage fl ange
from i nner bel t mol di ng at top of door.
Fig. 24 Front Door Reflector
Fig. 25 Door Sill Plate
23 - 34 BODY NS
(15) Ti l t top of tri m panel away from door to gai n
access to l atch l i nkage.
(16) Di sengage cl i p attachi ng l i nkage rod to i nsi de
l atch rel ease handl e (Fi g. 29).
(17) Separate l i nkage rod from l atch handl e.
(18) Remove front door tri m panel from vehi cl e.
INSTALLATION
(1) Hol d top of tri m panel away from door to gai n
access to l atch l i nkage.
(2) Pl ace l i nkage rod i n posi ti on on l atch handl e.
(3) Engage cl i p to hol d l i nkage rod to i nsi de l atch
rel ease handl e.
(4) Pl ace front door tri m panel i n posi ti on on door.
(5) I nstal l tri m panel i nto i nner bel t mol di ng at
top of door.
(6) I nstal l cl i ps to attach door tri m to door frame
around peri meter of panel .
(7) I f equi pped, i nstal l screw to attach door tri m to
door panel behi nd i nsi de l atch rel ease handl e.
(8) I f equi pped, connect power swi tch i nto wi re
connector.
(9) Pl ace power accessary swi tch i n posi ti on on
door tri m.
(10) Connect wi re connector i nto memory seat/mi r-
ror swi tch and i nstal l swi tch i nto tri m panel .
(11) I nstal l screws to attach accessary swi tch
panel to door tri m.
(12) I nstal l screw cover i nto swi tch panel .
(13) I f equi pped, i nstal l wi ndow crank.
(14) I f equi pped, i nstal l screws to attach tri m
panel to door i nsi de map pocket.
Fig. 26 Front Door Switch Panel
Fig. 27 Memory Seat/Mirror Switch
Fig. 28 Front Door Trim Panel
Fig. 29 Inside Door Handle Linkage
NS BODY 23 - 35
(15) I f equi pped, i nstal l screw to attach door pul l
cup to i nner door panel .
(16) I f equi pped, i nstal l screws to attach door
assi st handl e to i nner door panel .
(17) Connect wi re connector i nto courtesy l amp.
(18) I nstal l l amp i n door tri m.
FRONT DOOR WEATHER-STRIP
REMOVAL
(1) Open front door.
(2) Usi ng fork tool (C-4829), remove push-i n fas-
teners hol di ng front door weather-stri p to end frames
and bottom of door (Fi g. 30).
(3) Pul l weather-stri p from retai ni ng channel
around wi ndow frame.
(4) Remove weather-stri p from vehi cl e.
INSTALLATION
FRONT DOOR WINDOW CRANK
REMOVAL
(1) Usi ng a sui tabl e tool , di sengage cl i p hol di ng
wi ndow crank to regul ator shaft (Fi g. 31).
(2) Pul l wi ndow crank from regul ator shaft.
INSTALLATION
(1) Posi ti on wi ndow crank to regul ator shaft.
(2) Push wi ndow crank onto regul ator shaft to
engage retai ni ng cl i p.
FRONT DOOR WINDOW REGULATOR
REMOVAL
(1) Remove door tri m panel and water shi el d.
(2) Remove door gl ass retai ni ng cl i ps and al l ow
gl ass to rest on bottom of door.
(3) Di sconnect wi re connector from power wi ndow
motor, i f equi pped. Refer to Group 8S, Power Wi n-
dows, for proper procedures.
(4) Loosen screws attachi ng front and rear wi ndow
gui de rai l s to i nner door panel (Fi g. 32).
(5) Remove screw heads on gui de rai l s from key
hol e sl ots i n i nner door panel .
(6) Loosen screws attachi ng regul ator to i nner door
panel .
(7) Remove regul ator from i nner door panel .
(8) Extract rear gui de rai l through i nner door
panel rear access hol e (Fi g. 33).
(9) Extract front gui de rai l through front access
hol e.
Fig. 30 Front Door Weather-strip
Fig. 31 Window Crank
Fig. 32 Front Door Manual Window Regulator
23 - 36 BODY NS
INSTALLATION
(1) I nsert front gui de rai l through front access
hol e.
(2) I nsert rear gui de rai l through rear access hol e.
(3) Pl ace wi ndow regul ator i n posi ti on on i nner
door panel .
(4) Pl ace screw heads on gui de rai l s i n posi ti on
through key hol e sl ots i n i nner door panel .
(5) Ti ghten screws to attach front and rear gui de
rai l s to i nner door panel .
(6) Connect wi re connector i nto power wi ndow
(7) I nstal l door gl ass.
(8) Veri fy door gl ass al i gnment and operati on.
FRONT SEAT
REMOVAL
(1) From under vehi cl e, remove nuts attachi ng
front seat ri sers to the fl oor.
(2) Remove seat and ri ser from fl oor (Fi g. 34).
(3) Ti p seat rearward and di sconnect wi re connec-
tors from body harness, i f equi pped.
INSTALLATION
FRONT WHEELHOUSE SPLASH SHIELD
REMOVAL
(2) Remove front wheel . Refer to Group 22, Wheel s
and Ti res, for proper procedures.
(3) Remove push-i n fasteners hol di ng spl ash shi el d
to frame rai l forward of suspensi on.
(4) Remove push-i n fasteners hol di ng spl ash shi el d
to frame rai l rearward of suspensi on.
(5) Remove screws hol di ng wheel house spl ash
shi el d to front fender.
(6) Remove spl ash shi el d from vehi cl e (Fi g. 35).
INSTALLATION
(1) Pl ace spl ash shi el d i n posi ti on on vehi cl e (Fi g.
35).
(2) I nstal l screws to hol d wheel house spl ash shi el d
to front fender.
(3) I nstal l push-i n fasteners to hol d spl ash shi el d
to frame rai l rearward of suspensi on.
(4) I nstal l push-i n fasteners to hol d spl ash shi el d
to frame rai l forward of suspensi on.
(5) I nstal l front wheel . Refer to Group 22, Wheel s
and Ti res, for proper procedures.
Fig. 33 Front Door Power Window Regulator Fig. 34 Front Seat
Fig. 35 Front Wheelhouse Splash Shield
NS BODY 23 - 37
FUEL FILL DOOR BLOCKER LATCH
REMOVAL
(1) Remove l eft quarter tri m panel .
(2) Remove water shi el d patch coveri ng access hol e
i n C-pi l l ar.
(3) Di sengage l atch rel ease l i nk from cl i p on fuel
fi l l bl ocker l atch arm (Fi g. 38).
(4) Remove screws hol di ng fuel fi l l bl ocker l atch to
C-pi l l ar (Fi g. 36).
(5) Remove fuel fi l l bl ocker l atch from vehi cl e.
INSTALLATION
(1) Posi ti on fuel fi l l bl ocker l atch on vehi cl e.
(2) I nstal l screws to hol d fuel fi l l bl ocker l atch to
C-pi l l ar.
(3) Engage l atch rel ease l i nk i nto cl i p on fuel fi l l
bl ocker l atch arm wi th fuel door i n the cl osed posi -
ti on.
(4) I nstal l water shi el d patch to cover access hol e
i n C-pi l l ar.
(5) Veri fy fuel fi l l bl ocker l atch operati on.
(6) I nstal l l eft quarter tri m panel .
FUEL FILL DOOR BLOCKER LATCH STRIKER
REMOVAL
(2) Remove watershi el d as necessary to access
stri ker
(3) Remove screws hol di ng fuel fi l l door bl ocker
l atch stri ker to sl i di ng door rear end frame (Fi g. 37).
(4) Remove fuel fi l l door bl ocker l atch stri ker from
vehi cl e.
INSTALLATION
(1) Posi ti on fuel fi l l door bl ocker l atch stri ker on
vehi cl e.
(2) I nstal l screws to hol d fuel fi l l door bl ocker l atch
stri ker to sl i di ng door rear end frame.
(3) I nstal l sl i di ng door water shi el d.
(4) I nstal l sl i di ng door tri m panel .
FUEL FILL DOOR BLOCKER LOCKOUT LINK
REMOVAL
i n C-pi l l ar.
(3) Di sengage fuel fi l l er l ockout l i nk from cl i p on
fuel fi l l bl ocker l atch arm (Fi g. 38).
(4) Open fuel fi l l door.
(5) Remove screws hol di ng fuel fi l l er housi ng to
fuel fi l l er tube neck.
(6) Reachi ng i nsi de fuel fi l l er housi ng, rel ease cl i ps
hol di ng housi ng to outer quarter panel .
(7) Remove fuel fi l l er housi ng and l ockout l i nk
from vehi cl e.
(8) Di sengage cl i p hol di ng l i nk to fuel fi l l door
(Fi g. 39).
(9) Remove l i nk from fuel fi l l door.
Fig. 36 FUEL FILL DOOR BLOCKER LATCH
Fig. 37 Fuel Fill Door Blocker Latch Striker
Fig. 38 Fuel Filler Lockout Link at Latch Arm
23 - 38 BODY NS
INSTALLATION
(1) I nsert l i nk i nto cl i p on fuel fi l l door.
(2) Engage cl i p to hol d l i nk to fuel fi l l door.
(3) I nsert l ockout l i nk through grommet i n panel
between i nner and outer quarter panel .
(4) Cl ose fuel fi l l door.
(5) I nstal l fuel fi l l er housi ng to outer quarter
panel .
(6) Veri fy that al l cl i ps on fuel fi l l er housi ng are
ful l y engaged to outer quarter panel .
(7) Engage fuel fi l l er l ockout l i nk i nto cl i p on fuel
fi l l bl ocker l atch arm.
(8) I nstal l water shi el d patch coveri ng access hol e
i n C-pi l l ar.
FUEL FILLER HOUSING WITH BLOCKER LATCH
REMOVAL
i n C-pi l l ar.
(3) Di sengage l atch rel ease l i nk from cl i p on fuel
fi l l bl ocker l atch arm (Fi g. 38).
(4) Open fuel fi l l door.
(5) Remove screws hol di ng fuel fi l l neck to fuel
fi l l er housi ng.
(6) Posi ti on fuel fi l l neck out of the way.
(7) Reachi ng i nsi de fuel fi l l er housi ng, rel ease cl i ps
hol di ng housi ng to quarter panel (Fi g. 40).
(8) Remove fuel fi l l door from vehi cl e.
(9) Di sengage cl i p hol di ng l i nk to fuel fi l l door
(Fi g. 39).
(10) Remove l i nk from fuel fi l l door.
INSTALLATION
(1) I nstal l spri ng to housi ng and door
(2) Snap door i nto housi ng.
(3) I nsert l ockout l i nk i nto cl i p on fuel fi l l door.
(4) Engage cl i p to hol d l i nk to fuel fi l l door.
(5) I nsert l ockout l i nk through grommet i n panel
between i nner and outer quarter panel .
(6) Cl ose fuel fi l l door.
(7) I nstal l fuel fi l l er housi ng to outer quarter
panel .
(8) Veri fy that al l cl i ps on fuel fi l l er housi ng are
ful l y engaged to outer quarter panel .
(9) Pl ace fuel fi l l neck i n posi ti on.
(10) I nstal l screws to hol d fuel fi l l neck to fuel
fi l l er housi ng.
(11) Engage l atch rel ease l i nk i nto cl i p on fuel fi l l
bl ocker l atch arm.
(12) Veri fy fuel fi l l bl ocker l atch operati on.
(13) I nstal l water shi el d patch to cover access hol e
i n C-pi l l ar.
GRILLE
REMOVAL
(1) Remove front fasci a. Refer to Group 13, Frame
and Bumpers, for proper procedures.
(2) Di sengage cl i ps hol di ng gri l l e to front fasci a
(Fi g. 41).
(3) Remove pl asti c ri vets hol di ng gri l l e to fasci a.
(4) Remove gri l l e from fasci a.
INSTALLATION
(1) Posi ti on gri l l e on fasci a.
(2) I nstal l pl asti c ri vets to hol d gri l l e to fasci a.
(3) I nstal l cl i ps to hol d gri l l e to fasci a al ong bot-
tom of gri l l e.
(4) I nstal l front fasci a. Refer to Group 13, Frame
and Bumpers, for proper procedure.
HEADLINING
REMOVAL
(1) Remove sun vi sors and vani ty mi rrors.
(2) Remove sun vi sor center supports.
(3) I f equi pped, remove coat hooks.
(4) I f equi pped, remove roof rai l modul es.
Fig. 39 Fuel Filler Lockout Link
Fig. 40 Fuel Filler Housing and Door
NS BODY 23 - 39
(5) Remove A-pi l l ar tri m covers.
(6) Remove B-pi l l ar upper tri m covers.
(7) Remove C-pi l l ar upper tri m covers.
(8) Remove D-pi l l ar upper tri m covers.
(9) Remove rear door openi ng header tri m.
(10) I f equi pped, remove overhead consol e.
(11) I f equi pped, remove readi ng l amp.
(12) Remove dome l amp.
(13) Remove push-i n l ocki ng fasteners hol di ng
headl i ni ng to rear roof header (Fi g. 42) or (Fi g. 43).
(14) Remove headl i ni ng from roof.
(15) Extract headl i ni ng through rear door openi ng.
INSTALLATION
(1) I nsert headl i ni ng through rear door openi ng.
(2) Pl ace headl i ni ng i n posi ti on on roof.
(3) I nstal l l eft sun vi sor support.
(4) I nstal l push-i n l ocki ng fasteners to hol d head-
l i ni ng to rear roof header (Fi g. 42) or (Fi g. 43).
(5) I nstal l ri ght sun vi sor support.
(6) I nstal l sun vi sors and vani ty mi rrors.
(7) I f equi pped, i nstal l roof rai l modul es.
(8) I f equi pped, i nstal l coat hooks.
(9) I nstal l dome l amp.
(10) I f equi pped, i nstal l readi ng l amp.
(11) I f equi pped, i nstal l overhead consol e.
(12) I nstal l rear door openi ng header tri m.
(13) I nstal l D-pi l l ar upper tri m covers.
(14) I nstal l C-pi l l ar upper tri m covers.
(15) I nstal l B-pi l l ar upper tri m covers.
(16) I nstal l A-pi l l ar tri m covers.
HOOD
REMOVAL
(1) Rai se hood to ful l up posi ti on.
(2) Mark al l bol t and hi nge attachment l ocati ons
wi th a grease penci l or other sui tabl e devi ce to pro-
vi de reference marks for i nstal l ati on.
(3) Remove the top bol ts hol di ng hood to hi nge and
l oosen the bottom bol ts unti l they can be removed by
hand (Fi g. 44).
(4) Wi th assi stance from a hel per at the opposi te
si de of the vehi cl e to support the hood, remove bot-
tom bol ts hol di ng hood to hi nge.
(5) Remove the hood from the vehi cl e.
INSTALLATION
(1) Pl ace hood i n posi ti on on vehi cl e. Wi th assi s-
tance from a hel per at the opposi te si de of the vehi cl e
Fig. 41 Grille
Fig. 42 Headlining SWB
Fig. 43 Headlining LWB
23 - 40 BODY NS
to support the hood, i nstal l bottom bol ts to hol d hood
to hi nge fi nger ti ght.
(2) I nstal l top bol ts to hol d hood to hi nge fi nger
ti ght.
(3) Posi ti on bol ts at marks and ti ghten bol ts. The
hood shoul d be al i gned to 4 mm (0.160 i n.) gap to the
front fenders and fl ush across the top surfaces al ong
fenders.
(4) Veri fy hood operati on and al i gnment.
HOOD HINGE
REMOVAL
(1) Remove hood.
(2) Remove wi per uni t. Refer to Group 8K, Wi nd-
shi el d Wi pers and Washers, for procedure.
(3) Mark al l bol t and hi nge attachment l ocati ons
wi th a grease penci l or other sui tabl e devi ce to pro-
vi de reference marks for i nstal l ati on.
(4) Remove bol ts attachi ng body hal f of hood hi nge
to front fender fl ange and remove hi nge from vehi cl e
(Fi g. 45).
INSTALLATION
(1) I f necessary, pai nt new hi nge before i nstal l a-
ti on.
(2) Pl ace body hal f of hood hi nge i n posi ti on on
vehi cl e.
(3) I nstal l bol ts to hol d hood hi nge to front fender
fl ange.
(4) I nstal l wi per uni t. Refer to Group 8K, Wi nd-
shi el d Wi pers and Washers, for proper procedures.
(5) I nstal l hood.
(6) Al i gn al l marks and secure bol ts. The hood
shoul d be al i gned to 4 mm (0.160 i n.) gap to the front
fenders and fl ush across the top surfaces al ong fend-
ers. Shi ms can be added or removed under hood
hi nge to achi eve proper hood hei ght.
HOOD LATCH
REMOVAL
(2) Remove bol ts hol di ng hood l atch to radi ator cl o-
sure panel crossmember (Fi g. 46).
(3) Remove hood l atch from crossmember.
(4) Di sconnect hood rel ease cabl e from hood l atch
(Fi g. 47).
(5) Remove hood l atch from vehi cl e.
INSTALLATION
(1) Posi ti on hood l atch on vehi cl e.
(2) Connect hood rel ease cabl e from hood l atch.
(3) Posi ti on hood l atch on crossmember.
(4) Al i gn hood l atch by pl aci ng l atch over net-
pi erced tabs. I f al i gnment i s requi red, fl atten tabs.
(5) I nstal l bol ts attachi ng hood l atch to radi ator
cl osure panel crossmember.
(6) Veri fy hood operati on and al i gnment. Adjust as
necessary.
Fig. 44 Hood
Fig. 45 Hood Hinge
Fig. 46 Hood Latch
NS BODY 23 - 41
(7) Ti ghten attachi ng bol ts to 11 to 16 Nm (100 to
140 i n. l bs.) torque.
HOOD LATCH STRIKER
REMOVAL
(2) Remove bol ts hol di ng stri ker to i nsi de of hood
(Fi g. 44).
(3) Remove hood l atch stri ker from vehi cl e.
INSTALLATION
(1) Posi ti on hood l atch stri ker on vehi cl e.
(2) I nstal l bol ts to hol d hood l atch stri ker to hood.
(3) Al i gn hood l atch stri ker to engage smoothl y
i nto hood l atch.
(4) Veri fy hood operati on and al i gnment. Adjust as
necessary.
(5) Ti ghten attachi ng bol ts to 11 to 16 Nm (100 to
HOOD RELEASE CABLE
REMOVAL
(1) Remove hood l atch.
(2) Di sengage cabl e end from hood l atch l ocki ng
mechani sm.
(3) Sl i de cabl e case end si deways i n keyhol e sl ot of
hood l atch whi l e pi nchi ng barb on cabl e case cl osed.
(4) Remove cabl e from l atch (Fi g. 47).
(5) Remove hood rel ease handl e from i nstrument
panel .
(6) Di sengage rubber grommet cabl e i nsul ator
from hol e i n dash panel .
(7) Attach a sui tabl e l ength of mechani cs wi re to
l atch end of cabl e to assi st cabl e i nstal l ati on.
(8) Route cabl e back from l atch through engi ne
compartment toward dash panel near power brake
booster (Fi g. 48).
(9) Remove attachi ng cl i ps from cabl e case.
(10) From i nsi de vehi cl e, pul l cabl e through dash
panel unti l mechani cs wi re i s exposed.
(11) Di sconnect cabl e from mechani cs wi re.
(12) Remove hood rel ease cabl e from vehi cl e.
INSTALLATION
(1) Pl ace hood rel ease cabl e i n posi ti on under
i nstrument panel .
(2) Attach l atch end of hood rel ease cabl e to
mechani cs wi re protrudi ng through dash panel .
(3) Route cabl e forward through engi ne compart-
ment toward l atch by pul l i ng on mechani cs wi re
(Fi g. 48).
(4) Di sconnect mechani cs wi re from cabl e.
(5) Engage rubber grommet cabl e i nsul ator i nto
hol e i n dash panel .
(6) I nstal l hood rel ease handl e i nto i nstrument
panel .
(7) Pl ace cabl e i n posi ti on on l atch.
(8) Sl i de cabl e case end si deways i nto keyhol e sl ot
of hood l atch.
(9) Engage cabl e end i nto hood l atch l ocki ng mech-
ani sm.
(10) I nstal l hood l atch.
(11) I nstal l attachi ng cl i ps to cabl e case and i nstal l
cl i ps i nto ori gi nal hol es i n strut tower, fender, head-
l amp area, and radi ator cl osure panel crossmember.
HOOD RELEASE HANDLE
REMOVAL
bl ocker rei nforcement. Refer to Group 8E, I nstru-
ment Panel and Systems for proper procedures.
(2) Remove hood l atch cabl e.
(3) Remove screws hol di ng hood l atch rel ease han-
dl e to i nstrument panel brace (Fi g. 49).
(4) Remove hood l atch rel ease handl e from vehi cl e.
INSTALLATION
(1) Posi ti on hood l atch rel ease handl e on vehi cl e.
(2) I nstal l screws to hol d hood l atch rel ease handl e
to i nstrument panel brace.
Fig. 47 Hood Release Cable End Attachment
Fig. 48 Hood Release Cable Routing
23 - 42 BODY NS
(3) I nstal l hood l atch cabl e.
(4) I nstal l l ower steeri ng col umn cover and knee
JACK STORAGE COVER
LONG WHEEL BASE
REMOVAL
(1) Depress l atch handl e at top of jack storage
cover (Fi g. 50).
(2) Pul l outward at top of cover to di sengage l atch.
(3) Remove jack storage cover from vehi cl e.
INSTALLATION
(1) Pl ace jack storage cover i n posi ti on on vehi cl e.
(2) Al i gn gui de pi ns.
(3) Push i nward at top of cover to engage l atch
and fastener.
SHORT WHEEL BASE
REMOVAL
(1) Open quarter panel bi n storage cover.
(2) Li ft upward and rearward on jack storage cover
retai ni ng l atch to di sengage (Fi g. 51).
(3) Remove jack storage cover from vehi cl e.
INSTALLATION
(1) Posi ti on jack storage cover to vehi cl e.
(2) Snap storage cover l atch i nto posi ti on on quar-
ter tri m panel .
(3) Cl ose quarter tri m panel bi n storage cover.
LEFT D-PILLAR TRIM PANEL
REMOVAL
(1) Remove rear header tri m cover.
(2) Remove l i ftgate si l l pl ate.
(3) Remove second rear seat bel t turni ng l oop on
l ong wheel base vehi cl e.
(4) Remove bol t hol di ng second rear seat bel t
l ower anchor to quarter on short wheel base vehi cl e.
(5) Remove jack storage cover.
(6) Remove screws hol di ng tri m panel to D-pi l l ar
(Fi g. 52), (Fi g. 53), and (Fi g. 54).
(7) Di sengage hi dden cl i ps hol di ng tri m to D-pi l l ar.
(8) Di sconnect speaker wi re connector, i f equi pped.
(9) Pass seat bel t through sl ot i n D-pi l l ar tri m
panel on short wheel base vehi cl e.
(10) Remove D-pi l l ar tri m from vehi cl e.
INSTALLATION
(1) Pass seat bel t through sl ot i n D-pi l l ar tri m
panel on short wheel base vehi cl e.
(2) Posi ti on D-pi l l ar tri m panel on vehi cl e.
Fig. 49 Hood Release Handle
Fig. 50 Jack Storage Cover LWB
Fig. 51 Jack Storage Cover SWB
NS BODY 23 - 43
(3) Connect speaker wi re connector to speaker, i f
equi pped.
(4) Al i gn l ocati ng pi ns on backsi de of tri m panel to
mati ng hol es i n i nner quarter panel .
(5) Engage hi dden cl i ps to hol d tri m to D-pi l l ar.
(6) I nstal l screws to hol d tri m to D-pi l l ar.
(7) I nstal l jack storage cover.
(8) I nstal l bol t to hol d second rear seat bel t l ower
anchor to quarter on short wheel base vehi cl e.
Ti ghten al l seat bel t bol ts to 39 Nm (29 i n. l bs.).
(9) I nstal l second rear seat bel t turni ng l oop on
(10) I nstal l l i ftgate si l l pl ate.
(11) I nstal l rear header tri m cover.
LEFT QUARTER TRIM PANEL
REMOVAL
CAUTION: Disconnect the negative cable clamp
from battery post. Damage to accessory feed circuit
can result.
(2) Remove second rear seat, i f equi pped.
(3) Remove front door si l l pl ate on three door vehi -
cl e.
(4) Remove sl i di ng door si l l pl ate on four door
vehi cl e.
(5) Remove l eft quarter tri m bol ster.
(6) Remove upper l eft B-pi l l ar tri m on three door
vehi cl e.
(7) Remove C-pi l l ar tri m panel .
(8) Remove l eft D-pi l l ar tri m panel .
(9) Remove fi rst rear seat bel t anchor.
(10) Remove second rear seat bel t anchor on l ong
wheel base vehi cl e.
(11) Remove l eft front seat bel t openi ng bezel from
quarter tri m on three door vehi cl e.
(12) Remove screws hol di ng quarter tri m to quar-
ter panel i n B-pi l l ar area on three door vehi cl e (Fi g.
52) and (Fi g. 54).
(13) Remove screws hol di ng quarter tri m to quar-
ter panel from bol ster area (Fi g. 52), (Fi g. 53), and
(Fi g. 54).
(14) Remove screws hol di ng rear edge of quarter
tri m to attachi ng bracket or i nner quarter tri m
panel .
(15) Remove screws hol di ng top of tri m panel to
i nner sheet metal between B-pi l l ar and C-pi l l ar on
three door vehi cl e.
(16) Di sconnect wi re connector from accessory
power outl et, i f equi pped.
(17) Remove quarter tri m from quarter panel .
Fig. 52 Left Quarter and D-Pillar Trim Panels LWB 3 Door
23 - 44 BODY NS
(18) Pass front seat bel t and turni ng l oop through
sl ot i n quarter tri m panel on three door vehi cl e.
(19) Pass fi rst rear seat bel t through sl ot i n quar-
ter tri m panel .
(20) Pass second rear seat bel t, i f equi pped,
through sl ot i n quarter tri m panel on l ong wheel
base vehi cl e.
(21) Remove quarter tri m panel from vehi cl e.
INSTALLATION
(1) Posi ti on quarter tri m panel on vehi cl e.
(2) Pass second rear seat bel t, i f equi pped, through
sl ot i n quarter tri m panel on l ong wheel base vehi cl e.
(3) Pass fi rst rear seat bel t through sl ot i n quarter
tri m panel .
(4) Pass front seat bel t through sl ot i n quarter
tri m panel on three door vehi cl e.
(5) Connect wi re connector i nto accessory power
outl et, i f equi pped.
mati ng hol es i n i nner panel s.
(7) Posi ti on quarter tri m panel on i nner quarter
panel .
(8) I nstal l screws to hol d top of tri m panel to i nner
sheet metal between B-pi l l ar and C-pi l l ar on three
door vehi cl e.
(9) I nstal l screws to hol d rear edge of quarter tri m
to attachi ng bracket or i nner quarter panel .
(10) I nstal l screws to hol d quarter tri m to i nner
quarter panel i n bol ster area.
quarter panel i n B-pi l l ar area on three door vehi cl e.
(12) I nstal l l eft front seat bel t openi ng bezel i nto
quarter tri m on three door vehi cl e.
(13) I nstal l second rear seat bel ts anchor on l ong
wheel base vehi cl e. Ti ghten al l seat bel t bol ts to 39
(14) I nstal l fi rst rear seat bel t anchor.
(15) I nstal l l eft D-pi l l ar tri m panel .
(16) I nstal l C-pi l l ar tri m panel .
(17) I nstal l upper l eft B-pi l l ar tri m on three door
vehi cl e.
(18) I nstal l l eft quarter tri m bol ster.
(19) I nstal l front door si l l pl ate on three door vehi -
cl e.
(20) I nstal l sl i di ng door si l l pl ate on four door
vehi cl e.
(21) I nstal l second rear seat, i f equi pped.
(23) Connect the battery negati ve cabl e.
Fig. 53 Left Quarter and D-Pillar Trim Panels LWB Four Door
NS BODY 23 - 45
LIFTGATE
REMOVAL
(2) Remove screws hol di ng l i ftgate wi re connector
to rear header.
(3) Di sconnect l i ftgate wi re harness from body
wi re harness.
(4) Remove l i ftgate upper frame mol di ng.
(5) Di sconnect rear wi ndow washer hose from
spray nozzl e.
(6) Support l i ftgate on a sui tabl e l i fti ng devi ce.
(7) Remove screws hol di ng support cyl i nders to
l i ftgate.
(8) Remove bol ts hol di ng l i ftgate hi nge to roof
header (Fi g. 55).
(9) Wi th assi stance, remove l i ftgate from vehi cl e.
INSTALLATION
(1) Wi th assi stance, pl ace l i ftgate i n posi ti on on
vehi cl e.
(2) I nstal l bol ts to hol d l i ftgate hi nge to roof
header.
(3) I nstal l screws to hol d support cyl i nders to l i ft-
gate.
(4) Remove l i fti ng devi ce from under l i ftgate.
(5) Connect l i ftgate wi re harness i nto body wi re
harness.
(6) I nstal l screws to hol di ng wi re connector to rear
header.
(7) Connect rear wi ndow washer hose onto spray
nozzl e.
(8) I nstal l l i ftgate upper frame mol di ng.
Fig. 54 Left Quarter and D-Pillar Trim Panels SWB
Fig. 55 Liftgate
23 - 46 BODY NS
(9) Veri fy l i ftgate al i gnment. The l i ftgate shoul d
have a gap to adjacent panel s and fi t fl ush across the
gaps. The gap i s;
7 mm (0.280 i n.) to the fasci a,
6 mm (0.240 i n.) to the roof,
4 mm (0.160 i n.) to the aperture.
LIFTGATE CHMSL ACCESS PANEL
REMOVAL
(1) Usi ng a tri m sti ck (C-4755), di sengage cl i ps
hol di ng CHMSL access panel to l i ftgate tri m panel .
(2) Remove access panel from vehi cl e.
INSTALLATION
(1) Pl ace access panel i n posi ti on on vehi cl e.
(2) Engage cl i ps to hol d CHMSL access panel to
l i ftgate tri m panel .
LIFTGATE HINGE
REMOVAL
(3) Appl y several l ayers of duct tape on the outsi de
of to roof across the gap to the l i ft gate to hol d the
l i ftgate i n posi ti on.
(4) Remove bol ts hol di ng l i ftgate hi nge to roof
header.
(5) Remove bol ts hol di ng hi nge to l i ftgate (Fi g. 56).
(6) Remove hi nge from vehi cl e.
INSTALLATION
(1) I f necessary, pai nt repl acement hi nge before
i nstal l ati on.
(2) Pl ace hi nge i n posi ti on on vehi cl e.
(3) Al i gn hi nge to marks on l i ftgate.
(4) I nstal l bol ts to hol d hi nge to l i ftgate (Fi g. 56).
(5) Al i gn hi nge to marks on roof header.
(6) I nstal l bol ts to hol d l i ftgate hi nge to roof
header.
(7) Remove duct tape from roof and l i ftgate.
(9) Veri fy l i ftgate al i gnment. Refer to Li ftgate
Remove and I nstal l ati on for proper gap measure-
ments.
LIFTGATE LATCH
REMOVAL
(2) Di sengage outsi de handl e l i nk from cl i p on
l atch.
(3) Di sconnect wi re connector from l i ftgate ajar
swi tch (Fi g. 57).
(4) Remove screws hol di ng l atch to l i ftgate.
(5) Remove l atch from vehi cl e.
INSTALLATION
(1) Pl ace l atch i n posi ti on on vehi cl e.
(2) I nstal l screws to hol d l atch to l i ftgate.
(3) Pul l downward on outsi de handl e l i nk and
engage l i nk to cl i p on l atch.
(4) Connect wi re connector to l i ftgate ajar swi tch.
(5) Veri fy l i ftgate fi t and operati on. Adjust as nec-
essary.
LIFTGATE LATCH STRIKER
REMOVAL
(2) Mark outl i ne of stri ker on si l l to ai d i nstal l a-
ti on.
(3) Remove screws attachi ng stri ker to si l l (Fi g.
58).
(4) Remove stri ker from vehi cl e.
Fig. 56 Liftgate Hinge
Fig. 57 Liftgate Latch
NS BODY 23 - 47
INSTALLATION
(1) Pl ace stri ker i n posi ti on on vehi cl e.
(2) Al i gn stri ker to outl i ne mark on si l l .
(3) I nstal l screws to attach stri ker to si l l .
(4) Veri fy l i ftgate al i gnment and operati on.
LIFTGATE LOCK CYLINDER
REMOVAL
NOTE: Do not remove E-clip.
(1) Remove outsi de l i ftgate handl e.
(2) Remove l ock cyl i nder cl i p from handl e (Fi g. 59).
(3) Remove l ock cyl i nder and arm from handl e.
INSTALLATION
(1) I nstal l l ock cyl i nder cl i p i nto l i ftgate handl e.
(2) Push l ock cyl i nder i nto handl e unti l cl i p
engages groove i n l ock cyl i nder wi th an audi bl e cl i ck
(Fi g. 60).
(3) I nstal l outsi de l i ftgate handl e.
(4) Veri fy l ock cyl i nder operati on.
LIFTGATE OUTSIDE HANDLE
REMOVAL
(2) Remove power l ock motor.
(3) Di sengage outsi de handl e l i nk from cl i p on l i ft-
gate l atch.
(4) Di sconnect VTSS swi tch from back of l ock cyl -
i nder, i f equi pped.
(5) Di sengage l ock l i nk, i f equi pped.
(6) Remove nut attachi ng outsi de l i ftgate handl e to
l i ftgate (Fi g. 61).
(7) Di sengage retai ni ng groove hol di ng handl e to
l i ftgate.
(8) Remove outsi de l i ftgate handl e and l i nks from
vehi cl e.
INSTALLATION
(1) Posi ti on outsi de l i ftgate handl e and l i nks on
vehi cl e.
(2) Engage retai ni ng groove to hol d handl e to l i ft-
gate by pushi ng handl e to the ri ght for centeri ng.
(3) I nstal l nut to attach outsi de l i ftgate handl e to
l i ftgate.
Fig. 58 Liftgate Latch Striker
Fig. 59 Lock Cylinder Removal
Fig. 60 Lock Cylinder Installation
23 - 48 BODY NS
(4) Connect VTSS swi tch from back of l ock cyl i n-
der, i f equi pped.
(5) Engage outsi de handl e l i nk to cl i p on l i ftgate
l atch.
(6) I nstal l l ock l i nk, i f equi pped.
(7) I nstal l power l ock motor.
(8) Veri fy l i ftgate operati on. Adjust as necessary.
LIFTGATE PROP ASSEMBLY
REMOVAL
(3) Pul l l i ftgate openi ng weatherstri p from D-pi l l ar
fl ange next to prop assembl y end pi vot.
(4) Remove bol t hol di ng end pi vot to D-pi l l ar (Fi g.
62).
(5) Remove bol t hol di ng prop assembl y to l i ftgate.
(6) Remove prop assembl y from vehi cl e.
INSTALLATION
LIFTGATE SILL PLATE
REMOVAL
(1) Di sengage hi dden cl i ps hol di ng si l l pl ate to l i ft-
gate door openi ng si l l (Fi g. 63).
(2) Remove si l l pl ate from vehi cl e.
INSTALLATION
(2) Al i gn l ocator ri b i nto recess i n l i ftgate si l l .
(3) Engage hi dden cl i ps to hol d si l l pl ate to l i ftgate
door openi ng si l l .
LIFTGATE STABILIZER WEDGE
REMOVAL
(2) Mark outl i ne of stabi l i zer wedge on l i ftgate to
ai d i nstal l ati on.
(3) Remove ri vets attachi ng wedge to l i ftgate (Fi g.
64).
(4) Remove wedge from vehi cl e.
INSTALLATION
(1) Posi ti on stabi l i zer wedge on vehi cl e.
(2) Al i gn stabi l i zer wedge to outl i ne previ ousl y
made on l i ftgate.
(3) I nstal l ri vet to hol d wedge to l i ftgate.
(4) Veri fy l i ftgate fi t and operati on. Adjust as nec-
essary.
LIFTGATE STABILIZER WEDGE STRIKER
REMOVAL
Fig. 61 Liftgate Outside Handle Fig. 62 Liftgate Prop Assembly
Fig. 63 Liftgate Sill Plate
NS BODY 23 - 49
(2) Remove screws attachi ng stabi l i zer wedge
stri ker to D-pi l l ar (Fi g. 65).
(3) Retri eve shi ms from between wedge stri ker and
D-pi l l ar, i f necessary.
(4) Remove wedge stri ker from vehi cl e.
INSTALLATION
(1) Posi ti on wedge stri ker on vehi cl e.
(2) I nstal l any shi ms previ ousl y retri eved from
between wedge stri ker and D-pi l l ar or add shi ms to
ensure proper contact.
(3) I nstal l screws attachi ng stabi l i zer wedge
stri ker to D-pi l l ar (Fi g. 65).
LIFTGATE TRIM PANEL
REMOVAL
(2) Remove upper frame si de mol di ngs.
(3) Remove screws hol di ng assi st handl e to l i ftgate
and fasteners around the peri meter of the l ower tri m
panel .
(4) I f equi pped, usi ng a tri m sti ck (C-4755), pry
courtesy l amps from l i ftgate tri m.
(5) Di sconnect wi re connector from l amp.
(6) Remove CHMSL cover and fasteners hol di ng
the tri m panel .
(7) Di sengage hi dden cl i ps hol di ng tri m panel to
l i ftgate from around peri meter or l i ftgate (Fi g. 66).
(8) Remove l i ftgate tri m panel from vehi cl e.
INSTALLATION
(1) Pl ace l i ftgate tri m panel i n posi ti on on vehi cl e.
(2) Engage hi dden cl i ps to hol d tri m panel to l i ft-
gate and fasteners around peri meter of l i ftgate (Fi g.
66).
(3) I nstal l fasteners i nto tri m brackets and i nstal l
CHMSL cover.
(4) Connect wi re connector i nto l amp.
(5) I nstal l courtesy l amps i nto l i ftgate tri m.
(6) I nstal l screws to hol d assi st handl e to l i ftgate.
(7) I nstal l upper frame si de mol di ngs.
LIFTGATE UPPER FRAME MOLDING
REMOVAL
(2) Di sengage hi dden cl i ps hol di ng mol di ng to l i ft-
gate upper frame (Fi g. 66).
(3) Remove l i ftgate upper mol di ng from vehi cl e.
INSTALLATION
(1) Pl ace l i ftgate upper mol di ng i n posi ti on on
vehi cl e.
Fig. 64 Liftgate Wedge
Fig. 65 Liftgate Wedge Striker
Fig. 66 Liftgate Trim
23 - 50 BODY NS
(2) Engage hi dden cl i ps to hol d mol di ng to l i ftgate
upper frame (Fi g. 66).
LIFTGATE UPPER FRAME SIDE MOLDINGS
REMOVAL
(2) Di sengage hi dden cl i ps hol di ng si de mol di ngs
to l i ftgate upper frame (Fi g. 66).
(3) Remove l i ftgate upper frame si de mol di ng from
vehi cl e.
INSTALLATION
(1) Pl ace l i ftgate upper frame si de mol di ngs i n
posi ti on on vehi cl e.
(2) Engage hi dden cl i ps to hol d si de mol di ngs to
l i ftgate upper frame (Fi g. 66).
LOWER B-PILLAR TRIM COVER
REMOVAL
(1) Sl i de l ower seat bel t cover rearward to expose
anchor bol t.
(2) Remove bol t hol di ng l ower seat bel t anchor to
fl oor.
(3) Remove upper B-pi l l ar tri m cover.
(4) Remove access panel from B-pi l l ar tri m (Fi g.
67).
(5) Remove screw hol di ng l ower tri m cover to
B-pi l l ar from bel ow seat bel t retractor.
(6) Di sengage hi dden cl i ps hol di ng l ower tri m
cover to B-pi l l ar.
(7) Remove l ower B-pi l l ar tri m cover from vehi cl e.
INSTALLATION
(1) Pl ace l ower B-pi l l ar tri m cover i n posi ti on on
vehi cl e.
(2) I nsert seat bel t through hol e i n l ower B-pi l l ar
tri m.
(3) Engage hi dden cl i ps to hol d l ower tri m cover to
B-pi l l ar.
(4) I nstal l screw to hol d l ower tri m cover to B-pi l -
l ar bel ow seat bel t retractor.
(5) I nstal l access cover.
(6) I nstal l upper B-pi l l ar tri m cover.
(7) Pl ace seat bel t anchor i n posi ti on on fl oor so
webbi ng i s poi nted rearward and sl i ghtl y outboard.
(8) I nstal l bol t to hol d l ower seat bel t anchor to
fl oor. Ti ghten al l seat bel t bol ts to 39 Nm (29 i n.
l bs.) torque.
(9) Veri fy that seat bel t anchor does not i nterfere
wi th seat track travel .
LUGGAGE RACK CROSSBAR
REMOVAL
(1) Remove l uggage rack front ri ser covers.
(2) Di sengage l ock and sl i de crossbar forward i nto
notch i n front ri ser (Fi g. 68).
(3) Remove crossbar from roof.
Fig. 67 Lower B-pillar Trim Cover
Fig. 68 Luggage Rack Crossbar
NS BODY 23 - 51
INSTALLATION
(1) Pl ace crossbar i n posi ti on on roof.
(2) Engage crossbar i nto notch i n front ri ser.
(3) Sl i de crossbar rearward i nto desi red posi ti on.
(4) I nstal l l uggage rack front ri ser covers.
LUGGAGE RACK RISER COVER
REMOVAL
(1) Di sengage l ock tabs hol di ng l uggage rack front
ri ser cover to ri ser.
(2) Remove cover from ri ser (Fi g. 69).
INSTALLATION
(1) Pl ace cover i n posi ti on on l uggage rack ri ser.
(2) Engage l ock tabs to hol di ng l uggage rack front
ri ser cover to ri ser.
LUGGAGE RACK SIDE RAIL
REMOVAL
(1) Remove l uggage rack front ri ser covers.
(2) Remove crossbars.
(3) Remove screws attachi ng si de rai l to front ri ser
and roof panel (Fi g. 70).
(4) Remove screws attachi ng si de rai l to center
ri ser and roof panel .
(5) Remove screws attachi ng si de rai l to rear ri ser
and roof panel (Fi g. 71).
(6) Remove si de rai l from vehi cl e.
INSTALLATION
(1) Pl ace si de rai l i n posi ti on on vehi cl e.
(2) I nstal l screws to attach si de rai l to rear ri ser
and roof panel .
(3) I nstal l screws to attach si de rai l to center ri ser
and roof panel .
(4) I nstal l screws to attach si de rai l to front ri ser
and roof panel .
(5) I nstal l crossbars.
(6) I nstal l l uggage rack front ri ser covers.
OVERHEAD GRAB-HANDLES
REMOVAL
(1) Usi ng a tri m sti ck (C-4755), remove screw
access covers from grab-handl e.
(2) Remove screws hol di ng grab-handl e to roof rai l .
(3) Remove grab-handl e from vehi cl e.
INSTALLATION
(1) Pl ace grab-handl e i n posi ti on on vehi cl e.
(2) I nstal l screws to hol d grab-handl e to roof rai l .
(3) I nstal l screw access covers i nto grab-handl e.
QUARTER GLASS
REMOVAL
(1) Remove C-pi l l ar tri m.
(2) Open quarter gl ass to vent posi ti on.
(3) Remove screw attachi ng quarter wi ndow
retai ner to vent motor arm.
(4) Di sengage quarter wi ndow retai ner from vent
motor arm.
Fig. 69 Luggage Rack Riser Cover
Fig. 70 Luggage Rack Front Riser
Fig. 71 Luggage Rack Rear Riser
23 - 52 BODY NS
(5) Remove nuts hol di ng quarter gl ass to C-pi l l ar
(Fi g. 72).
(6) Remove quarter gl ass from vehi cl e.
INSTALLATION
(1) Pl ace quarter gl ass i n posi ti on on vehi cl e.
(2) I nstal l nuts to attach quarter gl ass to C-pi l l ar.
(3) Engage quarter wi ndow retai ner to vent motor
arm.
(4) I nstal l screw hol di ng quarter wi ndow retai ner
to vent motor arm.
(5) Cl ose quarter gl ass.
(6) I nstal l C-pi l l ar tri m.
QUARTER TRIM BOLSTER
The speaker gri l l e i n the quarter tri m bol ster i s
not removabl e. The tri m bol ster must removed to ser-
vi ce the speaker.
REMOVAL
(1) Di sengage hi dden cl i ps hol di ng tri m bol ster to
quarter tri m panel (Fi g. 73) and (Fi g. 74).
(2) Di sengage hook retai ner hol di ng front of tri m
bol ster to quarter tri m panel , i f appl i cabl e (Fi g. 73).
(3) Remove quarter tri m bol ster from vehi cl e.
INSTALLATION
(1) Pl ace quarter tri m bol ster i n posi ti on on vehi -
cl e.
(2) Engage hook retai ner to hol d front of tri m bol -
ster to quarter tri m panel , i f appl i cabl e.
(3) Engage hi dden cl i ps to hol d tri m bol ster to
quarter tri m panel .
RADIATOR CLOSURE PANEL CROSSMEMBER
REMOVAL
(2) Remove bol ts attachi ng hood l atch to cross-
member and posi ti on l atch out of the way.
(3) Remove radi ator si ght shi el d.
(4) Remove engi ne ai r i nl et resonator.
(5) Remove bol t hol di ng ai r cl eaner housi ng to
crossmember.
(6) Remove screw hol di ng cool ant recovery bottl e
to crossmember.
(7) Remove bol ts hol di ng radi ator i sol ators to
crossmember.
(8) Remove bol ts hol di ng ends of crossmember to
radi ator cl osure panel (Fi g. 75).
(9) Li ft crossmember upward and away from radi -
ator cl osure panel .
(10) Remove crossmember from vehi cl e.
INSTALLATION
(1) Pl ace radi ator cl osure panel crossmember i n
posi ti on on vehi cl e.
(2) I nsert ends of crossmember between l ayered
metal secti ons of radi ator cl osure panel at each si de
of radi ator.
Fig. 72 Quarter Glass
Fig. 73 Left Quarter Trim Bolster LWB Four Door
Fig. 74 Left Quarter Trim Bolster SWB and LWB
Three Door
NS BODY 23 - 53
(3) I nstal l bol ts to hol d ends of crossmember to
radi ator cl osure panel (Fi g. 75).
(4) I nstal l bol ts to hol d radi ator i sol ators to cross-
member.
(5) I nstal l screw to hol d cool ant recovery bottl e to
crossmember.
(6) I nstal l bol t to hol d ai r cl eaner housi ng to cross-
member.
(7) I nstal l engi ne ai r i nl et resonator.
(8) I nstal l radi ator si ght shi el d.
(9) Al i gn hood l atch by pl aci ng l atch over netpi erce
tabs. I f al i gnment i s requi red, fl atten tabs.
(10) I nstal l bol ts to hol d hood l atch to crossmem-
ber.
(11) Veri fy hood l atch operati on and hood al i gn-
ment.
RAIL LAMP MODULE
WITHOUT REAR HVAC
REMOVAL
(1) Pul l coat hook open.
(2) Remove screw attachi ng rai l l amp modul e to
roof rai l .
(3) Remove rai l l amp modul e from headl i ni ng (Fi g.
76).
(4) Di sconnect wi re connector from body wi ri ng
harness.
(5) Remove rai l l amp modul e from vehi cl e.
INSTALLATION
(1) Posi ti on rai l l amp modul e i n vehi cl e.
(2) Connect wi re connector to body wi ri ng harness.
(3) Posi ti on rai l l amp modul e to headl i ni ng.
(4) I nstal l screw attachi ng modul e to roof rai l
i nsi de coat hook.
WITH REAR HVAC
REMOVAL
(1) Pul l coat hook open.
(2) Remove screw attachi ng rai l l amp modul e to
roof rai l i nsi de coat hook (Fi g. 77).
(3) Remove screws attachi ng rai l l amp modul e to
roof rai l from behi nd grab handl e.
(4) Remove rai l l amp modul e from headl i ni ng.
(5) Di sconnect wi re connector from body wi ri ng
harness.
(6) Remove rai l l amp modul e from vehi cl e.
INSTALLATION
(1) Posi ti on rai l l amp modul e to vehi cl e.
(2) Connect wi re connector to body wi ri ng harness.
(3) Posi ti on rai l l amp modul e to headl i ni ng.
(4) I nstal l screws to attach rai l l amp modul e to
roof rai l behi nd grab handl e.
(5) I nstal l screw to attach rai l l amp modul e to roof
rai l i nsi de coat hook.
Fig. 75 Radiator Closure Panel Crossmember Fig. 76 Rail Lamp Module w/o Rear HVAC
Fig. 77 Rail Lamp Module w/Rear HVAC
23 - 54 BODY NS
REAR HVAC LOUVER AND BEZEL
REMOVAL
(1) Usi ng a tri m sti ck (C-4755), pry edge of l ouver
from bezel .
(2) Remove HVAC l ouver from bezel .
(3) Usi ng a tri m sti ck, pry l ower edge of HVAC
bezel away from headl i ni ng (Fi g. 78).
(4) Remove l ouver from vehi cl e.
INSTALLATION
(1) Pl ace bezel i n posi ti on i n HVAC duct openi ng.
(2) Push i nward on bezel unti l cl i ps snap i n pl ace.
Veri fy that al l four cl i ps have been engaged to the
bezel and that the bezel i s fl ush to the headl i ni ng
(3) Posi ti on HVAC l ouver to bezel .
(4) Snap both ends of the l ouver i nto HVAC bezel .
REAR HEADER TRIM
REMOVAL
(1) Di sengage hi dden cl i ps hol di ng tri m to rear
header (Fi g. 79).
(2) Separate rear header tri m from vehi cl e.
INSTALLATION
(1) Pl ace rear header tri m i n posi ti on on vehi cl e.
(2) Al i gn gui de pi ns on tri m to hol es i n header.
(3) Engage hi dden cl i ps to hol d tri m to rear
header.
RIGHT D-PILLAR TRIM PANEL
REMOVAL
(1) Remove rear header tri m cover.
(2) Remove l i ftgate si l l pl ate.
(3) Remove second rear seat bel t turni ng l oop on
(4) Remove bol t hol di ng second rear seat bel t, i f
equi pped, anchor to quarter on short wheel base
vehi cl e.
(5) Remove quarter tri m bol ster on short wheel
base vehi cl e.
(6) Remove screws hol di ng tri m panel to attachi ng
bracket on short wheel base vehi cl e (Fi g. 80).
(7) Di sengage hi dden cl i ps hol di ng tri m to D-pi l l ar
(Fi g. 80), (Fi g. 81), and (Fi g. 82).
(8) Remove D-pi l l ar tri m panel from D-pi l l ar.
(9) Di sconnect speaker wi re connector, i f equi pped.
sl ot i n tri m panel on short wheel base vehi cl e.
(11) Remove D-pi l l ar tri m from vehi cl e.
INSTALLATION
(1) Posi ti on D-pi l l ar tri m on vehi cl e.
sl ot i n tri m panel on short wheel base vehi cl e.
(3) Connect speaker wi re connector to speaker, i f
equi pped.
mati ng hol es i n D-pi l l ar.
(5) Engage hi dden cl i ps to hol d tri m to D-pi l l ar.
(6) I nstal l screws to hol d tri m panel to attachi ng
bracket on short wheel base vehi cl e.
(7) I nstal l quarter tri m bol ster on short wheel base
vehi cl e.
(8) I nstal l bol t to attach second rear seat bel t, i f
equi pped, anchor to quarter on short wheel base
vehi cl e. Ti ghten al l seat bel t bol ts to 39 Nm (29 i n.
l bs.) torque.
(9) I nstal l second rear seat bel t turni ng l oop on
(10) I nstal l l i ftgate si l l pl ate.
(11) I nstal l rear header tri m cover.
Fig. 78 Rear HVAC Louver
Fig. 79 Rear Header Trim
NS BODY 23 - 55
RIGHT QUARTER TRIM PANEL
REMOVAL
CAUTION: Disconnect the battery negative cable.
Damage to accessory feed circuit can result.
(2) Remove second rear seat, i f equi pped.
(3) Remove sl i di ng door si l l tri m panel .
(4) Remove quarter tri m bol ster.
(5) Remove C-pi l l ar tri m panel .
(7) Remove fi rst rear seat bel t anchor.
(8) Remove second rear seat bel t anchor on l ong
wheel base vehi cl e.
(9) Remove screws hol di ng quarter tri m to quarter
panel from bol ster area.
(10) Remove screws hol di ng rear edge of quarter
tri m to attachi ng bracket.
(11) Di sengage hi dden cl i ps hol di ng front of quar-
ter tri m to quarter panel rearward of sl i di ng door
openi ng.
(12) Remove quarter tri m from quarter panel .
(13) Di sconnect wi re connector from accessory
power outl et, i f equi pped.
(14) Pass second rear seat bel t through sl ot i n tri m
panel on l ong wheel base vehi cl e.
(15) Pass fi rst rear seat bel t through sl ot i n tri m
panel .
(16) Remove quarter tri m panel from vehi cl e.
INSTALLATION
(1) Posi ti on quarter tri m panel on vehi cl e.
(2) Pass fi rst rear seat bel t through sl ot i n tri m
panel .
(3) Pass second rear seat bel t through access hol e
i n tri m panel on l ong wheel base vehi cl e.
(4) Connect wi re connector i nto accessory power
outl et, i f equi pped.
mati ng hol es i n i nner quarter panel .
(6) Engage hi dden cl i ps to hol d front of quarter
tri m to quarter panel rearward of sl i di ng door open-
i ng.
(7) I nstal l screws to hol d rear edge of quarter tri m
to attachi ng bracket.
quarter panel i n bol ster area.
(9) I nstal l second rear seat bel t anchor on l ong
wheel base vehi cl e. Ti ghten al l seat bel t bol ts to 39
Fig. 80 Right Quarter and D-Pillar Trim Panels SWB
23 - 56 BODY NS
(10) I nstal l fi rst rear seat bel t anchor.
(11) I nstal l D-pi l l ar tri m panel .
(12) I nstal l C-pi l l ar tri m panel .
(13) I nstal l quarter tri m bol ster.
(14) I nstal l sl i di ng door si l l tri m panel .
(15) I nstal l second rear seat, i f equi pped.
(17) Connect the battery negati ve cabl e.
ROOF APERTURE (RAP) MOLDING
The RAP mol di ng i s set wi th body si de mol di ng
tape. The temperature i n the work area and the vehi -
cl e shoul d be at l east 21 C (70 F) to avoi d damag-
i ng the RAP mol di ngs.
REMOVAL
(1) Warm the affected sti ck-on mol di ng and body
metal to approxi matel y 38 C (100 F) usi ng a sui t-
abl e heat l amp or heat gun.
(2) Pul l sti ck-on mol di ng from pai nted surface.
(3) Remove adhesi ve tape resi due from pai nted
surface of vehi cl e. Use a 3M Scotch-Bri te Mol di ng
Adhesi ve and Stri pe Removal Di scs, or equi val ent, to
cl ean adhesi ve resi due from pai nted surfaces. The
adhesi ve removal di scs are avai l abl e from automoti ve
pai nt suppl i ers. Refer to i nstructi ons suppl i ed wi th
the di scs for proper usage.
INSTALLATION
(1) I f mol di ng i s to be reused;
(a) Remove tape resi due from mol di ng.
(b) Cl ean back of mol di ng wi th Mopar Super
Kl een sol vent, or equi val ent.
(c) Wi pe mol di ng dry wi th l i nt free cl oth.
(d) Appl y new body si de mol di ng (two si ded
adhesi ve) tape to back of mol di ng.
(2) Cl ean body surface wi th Mopar Super Kl een
sol vent, or equi val ent. Wi pe surface dry wi th l i nt free
cl oth.
(3) Remove protecti ve cover from tape on back of
mol di ng.
(4) Appl y mol di ng to body from front of vehi cl e to
rear.
(5) Usi ng a rol l er tool , rol l mol di ng onto body
panel wi th enough force to assure adhesi on and not
bend roof panel s.
SEAT BELT BUCKLE FRONT INBOARD
REMOVAL
(1) Remove screws hol di ng front i nboard si de cover
to seat cushi on frame.
(2) Remove si de cover from vehi cl e.
(3) Remove bol t hol di ng seat bel t buckl e to front
seat track (Fi g. 83).
Fig. 81 Right Quarter and D-Pillar Trim Panels LWB without Rear A\C
NS BODY 23 - 57
(4) Remove buckl e from vehi cl e. INSTALLATION
Ti ghten seat bel t anchor bol ts to 39 Nm (29 ft. l bs.)
torque.
SEAT BELT BUCKLE FIRST REAR TWO
PASSENGER BENCH
REMOVAL
Manual for proper procedures.
(2) Remove bol t attachi ng i nboard seat bel t/buckl e
to seat frame (Fi g. 84).
(3) Remove bel t from seat.
INSTALLATION
Ti ghten al l seat bel t anchor bol ts to 39 Nm (29 ft.
l bs.) torque.
SEAT BELT BUCKLE FIRST REAR QUAD BUCKET
REMOVAL
Manual for proper procedures.
(2) Remove screws attachi ng i nboard si de cover to
seat cushi on.
Fig. 82 Right Quarter and D-Pillar Trim Panels LWB with Rear A\C
Fig. 83 Seat Belt Buckle Front Inboard
23 - 58 BODY NS
(3) Remove si de cover from seat.
(4) Remove bol ts attachi ng recl i ner bracket to seat
cushi on.
(5) Remove recl i ner bracket from seat.
(6) Remove bol t attachi ng seat bel t buckl e to seat
track (Fi g. 83).
(7) Remove buckl e from vehi cl e.
INSTALLATION
l bs.) torque.
SEAT BELT BUCKLE SECOND REAR THREE
PASSENGER BENCH
REMOVAL
(1) Remove bol t attachi ng seat bel t buckl e to seat
rear frame rai l (Fi g. 85).
(2) Remove seat bel t buckl e from seat.
INSTALLATION
(1) Pl ace seat bel t buckl e i n posi ti on on seat.
(2) I nstal l bol t to attach seat bel t buckl e to seat
rear frame rai l . Ti ghten al l seat bel t bol ts to 39 Nm
SEAT BELT OUTBOARD FRONT
REMOVAL
(1) Remove shoul der harness hei ght adjuster knob
by pul l i ng i t strai ght away from adjuster.
(2) Remove cover from seat bel t turni ng l oop.
(3) Remove bol t hol di ng turni ng l oop to shoul der
bel t hei ght adjuster (Fi g. 86).
(4) Remove turni ng l oop from B-pi l l ar.
(5) Remove l ower B-pi l l ar tri m cover or quarter
tri m panel on three door l eft si de.
(6) Remove bol t hol di ng seat bel t retractor to
(7) Li ft retractor upward and di sengage arrow
head retai ner hol di ng retractor to B-pi l l ar.
(8) Remove seat bel t from vehi cl e.
INSTALLATION
l bs.) torque.
SEAT BELT FIRST REAR ANCHOR BRACKET LWB
REMOVAL
(1) Remove l ower quarter tri m panel .
(2) Remove bol t hol di ng fi rst rear seat bel t anchor
bracket to fl oor.
(3) Remove bracket from vehi cl e.
INSTALLATION
(1) Posi ti on bracket to vehi cl e.
(2) I nstal l bol t hol di ng fi rst rear seat bel t anchor
bracket to fl oor.
(3) I nstal l l ower quarter tri m panel .
Fig. 84 Seat Belt Buckle First Rear Two Passenger
Bench
Fig. 85 Seat Belt Buckle Second Rear Three
Passenger Bench
Fig. 86 Seat Belt Outboard Front
NS BODY 23 - 59
NOTE: The tightening specification for all seat belt
anchor bolts is 39 Nm (29 ft. lbs.) torque.
SEAT BELT FIRST REAR OUTBOARD LWB FOUR
DOOR
REMOVAL
(1) Remove fi rst and second rear seats. Refer to
Owners manual for proper procedures.
(3) Sl i de fl oor anchor cover from over the anchor
bol t.
(4) Remove fl oor anchor bol t.
(5) Remove anchor from fl oor.
(6) Open cl am shel l cover from over seat bel t turn-
i ng l oop.
bel t hei ght adjuster.
(8) Remove turni ng l oop from C-pi l l ar.
(10) Route seat bel t webbi ng and turni ng l oop
through access hol e i n l ower quarter tri m panel .
quarter panel .
head retai ner hol di ng retractor to quarter panel .
INSTALLATION
(1) Posi ti on seat bel t to vehi cl e.
(2) I nstal l arrow head retai ner to quarter panel
and push downward to seat retai ner.
(3) I nstal l bol t hol di ng seat bel t retractor to quar-
ter panel .
(5) I nstal l l ower quarter tri m panel .
(6) Posi ti on turni ng l oop to C-pi l l ar.
(7) I nstal l bol t hol di ng turni ng l oop to shoul der
(8) Cl ose cl am shel l cover from over seat bel t turn-
i ng l oop.
(9) Posi ti on anchor to fl oor.
(10) I nstal l fl oor anchor bol t.
(11) Sl i de fl oor anchor cover over the anchor bol t.
(12) I nstal l shoul der harness hei ght adjuster knob
by pushi ng i t strai ght onto adjuster.
(13) I nstal l fi rst and second rear seats. Refer to
NOTE: The tightening specification for all seat belt
anchor bolts is 39 Nm (29 ft. lbs.) torque.
SEAT BELT FIRST REAR OUTBOARD SWB FOUR
DOOR
REMOVAL
bol t.
(4) Remove fl oor anchor bol t (Fi g. 87).
i ng l oop.
(7) Remove bol t attachi ng turni ng l oop to shoul der
quarter panel (Fi g. 87).
head retai ner hol di ng retractor to quarter panel .
INSTALLATION
torque.
Fig. 87 Seat Belt First Rear Outboard SWB Four
Door
23 - 60 BODY NS
SEAT BELT LEFT FIRST REAR OUTBOARD LWB
THREE DOOR
REMOVAL
bol t.
i ng l oop.
(9) Remove C-pi l l ar upper tri m cover.
quarter panel .
head retai ner hol di ng retractor to quarter panel (Fi g.
88).
INSTALLATION
l bs.) torque.
SEAT BELT LEFT FIRST REAR OUTBOARD SWB
THREE DOOR
REMOVAL
bol t.
i ng l oop.
(7) Remove bol t attachi ng turni ng l oop to shoul der
(9) Remove B-pi l l ar upper tri m cover.
(10) Remove C-pi l l ar upper tri m cover.
quarter panel .
head retai ner hol di ng retractor to quarter panel (Fi g.
88).
INSTALLATION
l bs.) torque.
SEAT BELT SECOND REAR OUTBOARD SWB
REMOVAL
(2) Sl i de l ower anchor cover from over the anchor
shoul der-nut.
(3) Remove l ower anchor shoul der-nut.
(4) Remove l ower anchor from wheel house (Fi g.
89).
through access hol e i n quarter tri m.
(7) Remove bol ts attachi ng seat bel t gui de l oop to
i nner quarter panel .
(8) Remove anchor bol t attachi ng retractor to
(9) Remove second rear seat bel t retractor from
vehi cl e (Fi g. 89).
Fig. 88 Seat Belt Left First Rear Outboard SWB
Three Door
NS BODY 23 - 61
INSTALLATION
Ti ghten al l seat bel ts to 39 Nm (29 ft. l bs.) torque.
SEAT BELT SECOND RIGHT REAR OUTBOARD
LWB
REMOVAL
shoul der-nut.
(3) Remove l ower anchor shoul der-nut (Fi g. 90).
(4) Remove l ower anchor from wheel house.
(5) Fol d upper turni ng l oop extensi on cover down-
ward to gai n access to anchor bol t.
(6) Remove bol t hol di ng turni ng l oop to extensi on
bracket above quarter gl ass (Fi g. 90).
(7) Remove turni ng l oop from extensi on bracket.
(11) Remove bol t attachi ng retractor to i nner quar-
ter panel (Fi g. 90).
(12) Remove screw attachi ng retractor to i nner
quarter panel .
vehi cl e.
INSTALLATION
(1) Posi ti on second rear seat bel t retractor i n vehi cl e.
(2) I nstal l screw attachi ng retractor to i nner quar-
ter panel .
(3) I nstal l bol t to attach retractor to i nner quarter
panel .
(7) Posi ti on turni ng l oop to extensi on bracket.
(8) I nstal l bol t to hol d turni ng l oop to extensi on
bracket above quarter gl ass. Ti ghteni ng speci fi cati ons
for al l seat bel t bol ts i s 39 Nm (29 ft. l bs.) torque.
(9) I nstal l upper turni ng l oop extensi on cover.
(10) Posi ti on l ower anchor to wheel house.
(11) I nstal l l ower anchor shoul der-nut.
(12) I nstal l l ower anchor cover over the anchor
shoul der-nut.
(13) I nstal l second rear seat to vehi cl e. Refer to
SECOND RIGHT REAR OUTBOARD SEAT BELT
LWB W/REAR HVAC
REMOVAL
shoul der-nut.
(3) Remove l ower anchor shoul der-nut.
(4) Remove l ower anchor from wheel house.
(5) Fol d upper turni ng l oop extensi on cover down-
ward to gai n access to anchor bol t.
Fig. 89 Seat Belt Second Rear Outboard SWB Fig. 90 Second Right Rear Outboard Seat Belt
LWB
23 - 62 BODY NS
(6) Remove bol t attachi ng turni ng l oop to exten-
si on bracket above quarter gl ass.
(7) Remove turni ng l oop from extensi on bracket.
(10) Remove quarter tri m panel as necessary to
gai n access to HVAC uni t.
(12) Loosen HVAC uni t enough to gai n access to
seat bel t retractor fasteners.
(a) Remove bracket around HVAC uni t (Fi g. 91).
(b) Remove ai r duct (Fi g. 92).
(c) Remove fasteners hol di ng HVAC uni t to
i nner quarter panel (Fi g. 93).
(d) Remove screws attachi ng upper evaporator
housi ng to l ower evaporator housi ng.
(e) Remove cool ant l i ne retai ni ng bracket hol d-
down bol t.
(13) Remove bol ts attachi ng seat bel t gui de l oop to
(14) Pul l outward on HVAC uni t and remove bol t
hol di ng retractor to i nner quarter panel .
(15) Remove screw attachi ng retractor to i nner
quarter panel .
vehi cl e.
INSTALLATION
(1) Posi ti on second rear seat bel t retractor to vehi -
cl e.
(2) I nstal l screw attachi ng retractor to i nner
quarter panel .
(3) Pul l outward on HVAC uni t and i nstal l bol t
attachi ng retractor to i nner quarter panel .
(4) I nstal l bol ts attachi ng seat bel t gui de l oop to
(5) I nstal l cool ant l i ne retai ni ng bracket hol down
bol t.
(6) I nstal l screws hol di ng upper evaporator hous-
i ng to l ower evaporator housi ng.
(7) I nstal l fasteners attachi ng HVAC uni t to i nner
quarter panel .
(8) I nstal l ai r duct.
(9) I nstal l bracket around HVAC uni t.
(11) I nstal l quarter tri m panel as necessary to gai n
access to HVAC uni t.
(14) Posi ti on turni ng l oop to extensi on bracket.
(15) I nstal l bol t attachi ng turni ng l oop to exten-
si on bracket above quarter gl ass.
(16) Pul l upper turni ng l oop extensi on cover
upward over anchor bol t.
(17) I nstal l l ower anchor shoul der-nut.
(18) Sl i de l ower anchor cover over anchor shoul der-
nut.
(19) I nstal l second rear seat from vehi cl e. Refer to
Fig. 91 Trim Panel Mounting Bracket
Fig. 92 Lower Heater Duct
Fig. 93 Rear HVAC Mounting
NS BODY 23 - 63
SHOULDER BELT HEIGHT ADJUSTER B OR
C-PILLAR
REMOVAL
(1) Remove B or C-pi l l ar tri m cover.
(2) Remove screws hol di ng shoul der bel t hei ght
adjuster to pi l l ar.
(3) Remove hei ght adjuster from vehi cl e (Fi g. 94).
INSTALLATION
torque.
SHOULDER BELT HEIGHT ADJUSTER KNOB
REMOVAL
(1) Di sengage cl i ps hol di ng cl am shel l cover to seat
bel t turni ng l oop and open cover.
(2) Usi ng a Snap-on tri m tool , pry knob from
shoul der bel t hei ght adjuster (Fi g. 95).
INSTALLATION
(1) Pl ace shoul der bel t hei ght adjuster knob i n
posi ti on on hei ght adjuster.
(2) Push knob on unti l retai ners engage.
SIDE VIEW MIRROR
REMOVAL
(1) Rel ease front door l atch and open door.
(2) Remove screw hol di ng mol di ng to base of si de
vi ew mi rror (Fi g. 96).
(3) Remove mol di ng from mi rror.
(4) Remove bol ts hol di ng bottom of si de vi ew mi r-
ror to A-pi l l ar.
(5) Remove bol t attachi ng top of si de vi ew mi rror
to A-pi l l ar (Fi g. 96).
(6) I f equi pped, di sconnect power si de vi ew mi rror
wi re connector from i nstrument panel harness.
(7) Remove si de vi ew mi rror from vehi cl e.
INSTALLATION
(1) Connect power si de vi ew mi rror wi re connector
i nto i nstrument panel harness, i f equi pped.
(2) Pl ace si de vi ew mi rror i n posi ti on on vehi cl e
(Fi g. 96).
(3) I nstal l bol t to hol d top of si de vi ew mi rror to
A-pi l l ar.
(4) I nstal l bol ts to hol d bottom of si de vi ew mi rror
to A-pi l l ar.
(5) Pl ace mol di ng i n posi ti on on mi rror.
(6) I nstal l screw to hol d mol di ng to base of si de
vi ew mi rror.
SLIDING DOOR
CAUTION: Apply several layers of masking tape to
the body around the rear end of the upper roller
channel and the forward edge of the quarter panel,
to avoid damaging the paint.
Fig. 94 Shoulder Belt Height Adjuster
Fig. 95 Shoulder Belt Height Adjuster Knob
Fig. 96 Side View Mirror
23 - 64 BODY NS
REMOVAL
(1) Appl y maski ng tape to outsi de surface of quar-
ter panel bel ow the center rol l er channel , rearward of
the door openi ng.
(2) Rel ease sl i di ng door l atch and open door.
(3) Appl y maski ng tape to door jamb area, rear-
ward of the upper rol l er channel .
(4) Remove screw hol di ng upper rol l er arm stop
bumper to upper rol l er arm (Fi g. 97).
(5) Remove stop bumper from upper rol l er arm.
(6) Remove center stop bumper tri m cover from
sl i di ng door (Fi g. 98).
(7) Remove center stop from sl i di ng door.
(8) Remove sl i di ng door si l l pl ate.
(9) Remove hol d open l atch stri ker (Fi g. 99).
(10) Open quarter gl ass.
(11) Remove center rol l er channel end cover (Fi g.
100).
(12) Support sl i di ng door on a sui tabl e l i fti ng
devi ce wi th a padded upper surface. The door must
be moveabl e wi th l i fti ng devi ce i n pl ace.
CAUTION: Do not allow the center hinge roller to
contact the quarter glass. Glass can break.
(13) Rol l door rearward unti l l ower rol l ers di sen-
gage from l ower channel .
(14) Rol l the door rearward unti l the upper (Fi g.
101) and center hi nge rol l ers exi t the upper and cen-
ter channel s (Fi g. 102).
(15) Remove sl i di ng door from vehi cl e.
INSTALLATION
(1) Pl ace sl i di ng door i n posi ti on on l i fti ng devi ce.
(2) Posi ti on door rearward of the sl i di ng door open-
i ng.
CAUTION: Do not allow the center hinge roller to
contact the quarter glass. Glass can break.
(3) Engage the center hi nge rol l ers i nto the center
channel s (Fi g. 102).
(4) Rol l door forward unti l l ower rol l ers engage
i nto rear of l ower channel .
(5) Engage the upper hi nge i nto the upper chan-
nel s (Fi g. 101).
(6) I nstal l hol d open l atch stri ker (Fi g. 99).
(7) I nstal l sl i di ng door si l l pl ate.
Fig. 97 Sliding Door Upper Stop
Fig. 98 Sliding Door Center Stop Bumper
Fig. 99 Sliding Door Hold Open Latch Striker
Fig. 100 Center Channel End Cover
NS BODY 23 - 65
(8) I nstal l center rol l er channel end cover (Fi g.
100).
(9) I nstal l center stop on sl i di ng door (Fi g. 98).
(10) I nstal l center stop bumper tri m cover on sl i d-
i ng door.
(11) Pl ace upper rol l er stop bumper i n posi ti on on
upper rol l er arm.
(12) I nstal l screw to hol d upper rol l er arm stop
bumper to upper rol l er arm (Fi g. 97).
(13) Remove maski ng tape from body surfaces.
(14) Veri fy door operati on and fi t. Adjust as neces-
sary.
SLIDING DOOR CENTER HINGE
REMOVAL
(1) Open sl i di ng door to the mi d poi nt of i ts travel .
devi ce.
(3) Mark outl i ne of center hi nge of i nner door
panel to ai d i nstal l ati on.
(4) Remove bol ts hol di ng center hi nge to sl i di ng
door.
(5) Remove center hi nge from sl i di ng door.
(6) Rol l center hi nge to rear of rol l er channel .
(7) Separate center hi nge from vehi cl e.
INSTALLATION
NOTE: Center hinge has an adjustable bolt for
up/down alignment. Refer to Siding Door Center
Hinge Adjustment.
(1) Pl ace center hi nge i n posi ti on on vehi cl e.
(2) Rol l center hi nge forward i n rol l er channel .
(3) Pl ace center hi nge i n posi ti on on sl i di ng door
and al i gn marks.
(4) I nstal l bol ts to hol d center hi nge to sl i di ng
door.
(5) Veri fy sl i di ng door al i gnment and operati on.
SLIDING DOOR CENTER STOP TRIM COVER
REMOVAL
(1) Usi ng a tri m sti ck (C-4755), di sengage cl i ps
hol di ng center stop tri m cover from door tri m panel .
(2) Remove tri m cover from vehi cl e (Fi g. 103).
INSTALLATION
Fig. 101 Sliding Door Upper Roller
Fig. 102 Sliding Door Center Roller
Fig. 103 Sliding Door Center Stop Trim Cover
23 - 66 BODY NS
SLIDING DOOR CENTER STRIKER ASSEMBLY
REMOVAL
(2) Remove screws attachi ng center stri ker assem-
bl y to door end frame (Fi g. 104).
(3) Remove center stri ker assembl y from door
through access hol e.
INSTALLATION
(1) Pl ace center stri ker i n posi ti on on door through
access hol e.
(2) I nstal l screws to attach center stri ker to door
end frame.
SLIDING DOOR HOLD OPEN LATCH
REMOVAL
(1) Open sl i di ng door.
(3) Remove nuts hol di ng hol d open l atch to l ower
rol l er arm (Fi g. 105).
(4) Separate hol d open l atch from l ower arm.
(5) Di sconnect cabl e from hol d open l atch.
(6) Remove hol d open l atch from vehi cl e.
INSTALLATION
(1) Pl ace hol d open l atch i n posi ti on on vehi cl e.
(2) Connect cabl e to hol d open l atch.
(3) Pl ace hol d open l atch i n posi ti on on l ower arm.
(4) I nstal l nuts to hol d the hol d open l atch to
l ower rol l er arm.
(6) Veri fy sl i di ng door operati on.
SLIDING DOOR HOLD OPEN LATCH STRIKER
REMOVAL
(1) Open sl i di ng door, do not l atch open.
(3) Remove screws hol di ng sl i di ng door hol d open
l atch stri ker to door si l l (Fi g. 106).
(4) Remove hol d open l atch stri ker from vehi cl e.
INSTALLATION
(1) Pl ace hol d open l atch stri ker i n posi ti on on
vehi cl e.
(2) I nstal l screws to hol d sl i di ng door hol d open
l atch stri ker to door si l l .
Fig. 104 Sliding Door Center Striker Assembly
Fig. 105 Sliding Door Hold Open Latch
Fig. 106 Sliding Door Hold Open Latch Striker
NS BODY 23 - 67
REMOVAL
(1) Remove sl i di ng door upper mol di ng as neces-
sary to gai n access to upper door handl e fastener.
(3) Remove screws hol di ng bottom of i nsi de l atch
handl e to sl i di ng door (Fi g. 107).
(4) Remove screw hol di ng top of i nsi de l atch han-
dl e to sl i di ng door.
(5) Di sengage cabl e end from cl i p on bel l crank
assembl y.
(6) Di sengage cabl e end from bel l crank assembl y.
(7) Remove l atch handl e from sl i di ng door.
(8) Remove push-i n fastener hol di ng cabl e end to
l atch handl e.
(9) Di sengage cabl e casi ng end from l atch handl e
(Fi g. 108).
(10) Di sengage cabl e end from l atch handl e.
(11) Remove handl e from vehi cl e.
INSTALLATION
(1) Pl ace i nsi de l atch handl e i n posi ti on on vehi cl e.
(2) Engage cabl e end i nto l atch handl e.
(3) Engage cabl e casi ng end i nto l atch handl e.
(4) I nstal l push-i n fastener to hol d cabl e i nto l atch
handl e.
(5) Pl ace l atch handl e i n posi ti on on sl i di ng door.
(6) I nstal l screw to hol d top of i nsi de l atch handl e
to sl i di ng door.
(7) I nstal l screws to hol d bottom of i nsi de l atch
handl e to sl i di ng door.
(8) Engage cabl e end i nto bel l crank assembl y.
(9) Engage cl i p to hol d cabl e end i nto bel l crank
assembl y.
(10) Veri fy sl i di ng door operati on. Adjust as neces-
sary.
(12) I nstal l sl i di ng door upper mol di ng.
BELLCRANK
REMOVAL
(2) Remove watershi el d as necessary to gai n access
to l atch bel l crank.
(4) Di sengage cl i p hol di ng i nsi de rel ease bel l crank
l i nk to l atch/l ock control .
(5) Separate bel l crank l i nk from l atch/l ock control .
(6) Di sengage cl i p hol di ng rel ease handl e l atch
cabl e to bel l crank.
(7) Remove cabl e from bel l crank.
(8) Remove screw hol di ng bel l crank to i nner door
panel (Fi g. 109).
(9) Remove bel l crank from vehi cl e.
Fig. 107 Sliding Door Inside Handle
Fig. 108 Sliding Door Handle Cable
Fig. 109 Inside Latch Handle Bellcrank
23 - 68 BODY NS
INSTALLATION
(1) Posi ti on bel l crank on vehi cl e.
(2) I nstal l screw hol di ng bel l crank to i nner door
panel .
(3) Posi ti on cabl e from bel l crank.
(4) Engage cl i p to hol d rel ease handl e l atch cabl e
to bel l crank.
(5) Posi ti on bel l crank l i nk on l atch/l ock control .
(6) Engage cl i p to hol d i nsi de rel ease bel l crank
l i nk to l atch/l ock control .
(7) I nstal l l atch/l ock control cover.
(8) I nstal l watershi el d.
SLIDING DOOR INSIDE LATCH RELEASE
MECHANISM
REMOVAL
(1) Remove sl i di ng door i nsi de l atch handl e.
(2) Remove push-i n fastener hol di ng cabl e end to
rel ease mechani sm (Fi g. 108).
(3) Di sengage cabl e end from rel ease mechani sm.
(4) Di sengage l atch cabl e from assi st handl e.
(5) Remove screws hol di ng rel ease mechani sm to
handl e (Fi g. 110).
(6) Remove rel ease mechani sm from handl e.
(7) Rotate l atch rel ease button away from mecha-
ni sm unti l fl ats on button pi vots al i gn wi th sl ots i n
mechani sm (Fi g. 111).
(8) Remove button from rel ease mechani sm.
INSTALLATION
(1) Posi ti on button on rel ease mechani sm.
(2) Al i gn and engage fl ats on button pi vots i nto
sl ots i n mechani sm (Fi g. 111).
(3) Rotate l atch rel ease button i nto mechani sm.
(4) Pl ace rel ease mechani sm i n posi ti on on handl e.
(5) I nstal l screws to hol d rel ease mechani sm to
handl e (Fi g. 110).
(6) Engage l atch cabl e i nto handl e.
(7) Engage cabl e end from rel ease mechani sm.
(8) I nstal l push-i n fastener hol di ng cabl e end to
rel ease mechani sm.
(9) I nstal l sl i di ng door i nsi de l atch handl e.
SLIDING DOOR LATCH STRIKER
REMOVAL
(2) Mark outl i ne of stri ker on C-pi l l ar door jamb
face to ai d i nstal l ati on.
(3) Remove screws hol di ng stri ker to C-pi l l ar (Fi g.
112).
(4) Remove stri ker from vehi cl e.
INSTALLATION
(1) Pl ace stri ker i n posi ti on on vehi cl e.
(2) Al i gn stri ker to outl i ne marks on C-pi l l ar.
(3) I nstal l screws to hol d stri ker to C-pi l l ar.
Fig. 110 Sliding Door Inside Latch Release
Mechanism
Fig. 111 Sliding Door Inside Latch Button
Fig. 112 Sliding Door Latch Striker
NS BODY 23 - 69
SLIDING DOOR LATCH/LOCK CONTROL
REMOVAL
(2) Remove sl i di ng door stop bumper.
(3) Remove sound pad, i f equi pped.
(4) Remove l atch/l ock control cover (Fi g. 113).
(5) Wi th sl i di ng door ajar, di sengage cl i p hol di ng
rear l atch l i nk to l atch/l ock control (Fi g. 114) (Fi g.
115).
(6) Pl ace a fl at head screw dri ver between metal
cl i p ears and bottom of l i nk.
NOTE: Rotate screw driver to remove link.
CAUTION: Replace the latch/lock control if any of
the metal clips on the latch/lock control are bent or
broken. DO NOT attempt to repair the clips to retain
the links.
(7) Remove rear l atch l i nk from l atch/l ock control .
(8) Di sengage cl i p hol di ng outsi de door handl e l i nk
to l atch/l ock control (Fi g. 115).
(9) Remove outsi de door handl e l i nk from l atch/
l ock control .
(10) Di sengage cl i p hol di ng i nsi de door handl e
bel l crank l i nk to l atch/l ock control (Fi g. 115).
(11) Separate i nsi de door handl e bel l crank l i nk
from l atch/l ock control .
(12) Di sengage cl i p hol di ng l ock cyl i nder l i nk to
l atch/l ock control .
(13) Remove l ock cyl i nder l i nk from control .
(14) Di sengage cl i p hol di ng i nsi de l ock l i nk to
(15) Remove i nsi de l ock l i nk from control .
(16) Di sengage l ock tabs hol di ng hol d open l atch
cabl e case to l atch/l ock control .
(17) Remove hol d open l atch cabl e bal l end from
(18) Loosen bol ts hol di ng l atch/l ock control to sl i d-
i ng door.
(19) I f equi pped, di sconnect wi re connector from
power door l ock motor.
(20) Remove l atch/l ock from vehi cl e.
INSTALLATION
(1) Posi ti on l atch/l ock l ocki ng l ever i n unl ocked
posi ti on.
(2) Engage ri ggi ng cam (Fi g. 114).
(3) Pl ace l atch/l ock i n posi ti on on vehi cl e.
(4) I f equi pped, engage wi re connector i nto power
door l ock motor.
(5) I nsert bol t heads i nto sl ots i n sl i di ng door
i nner panel .
(6) Ti ghten bol ts to hol d l atch/l ock control to sl i d-
i ng door.
(7) Engage hol d open l atch cabl e bal l end i nto
(8) Engage l ock tabs to hol d the hol d open l atch
cabl e case to l atch/l ock control .
(9) I nsert l ock cyl i nder l i nk i nto control .
(10) Engage cl i p to hol d l ock cyl i nder l i nk to l atch/
l ock control .
(11) I nsert i nsi de l ock l i nk i nto control .
(12) Engage cl i p to hol d i nsi de l ock l i nk to l atch/
l ock control .
(13) Li ft cl i p for i nsi de door handl e bel l crank l i nk
to top of sl ot i n mechani sm (Fi g. 114).
(14) Engage cl i p to hol d bel l crank l i nk to l atch/l ock
control .
(15) Lower cl i p for outsi de door handl e l i nk to bot-
tom of sl ot i n mechani sm and engage l i nk to cl i p
(Fi g. 114).
NOTE: Move link rearward until movement stops
before engaging link to clip.
(16) Pl ace rear l atch l i nk i n posi ti on on control by
movi ng l i nk rearward unti l movement stops.
(17) Engage cl i p to hol d rear l atch rel ease l i nk to
(18) Push i nsi de l ock l i nk button downward to di s-
engage ri ggi ng cam.
(20) I nstal l l atch/l ock cover.
(21) I nstal l sound pad, i f equi pped.
(22) I nstal l sl i di ng door stop bumper.
Fig. 113 Latch/Lock Cover
23 - 70 BODY NS
SLIDING DOOR LOWER ROLLER ARM
REMOVAL
(2) Mark outl i ne of rol l er arm on sl i di ng door
bracket to ai d i nstal l ati on.
(4) Remove screws hol di ng hol d open l atch to
l ower rol l er arm.
(5) Separate hol d open l atch from l ower arm.
(6) Support sl i di ng door on a sui tabl e l i fti ng devi ce
wi th a padded upper surface. The door must be
moveabl e wi th l i fti ng devi ce i n pl ace.
(7) Remove bol ts hol di ng l ower rol l er arm to sl i d-
i ng door (Fi g. 116).
(8) Remove rol l er arm from sl i di ng door.
(9) Di sengage rol l er arm from l ower channel (Fi g.
117).
(10) Remove rol l er arm from vehi cl e.
INSTALLATION
SLIDING DOOR LOWER ROLLER ARM BRACKET
REMOVAL
(1) Remove access hol e pl ug.
devi ce.
(4) Remove l ower rol l er arm.
(5) Mark outl i ne of rol l er arm bracket on i nsi de of
sl i di ng door.
(6) Remove bol ts hol di ng l ower rol l er arm bracket
to sl i di ng door (Fi g. 118).
(7) Remove l ower rol l er bracket from vehi cl e.
Fig. 114 Sliding Door Latch/Lock Control Linkage
Fig. 115 Latch/Lock Control Link Removal
NS BODY 23 - 71
INSTALLATION
(1) Pl ace l ower rol l er bracket i n posi ti on on vehi -
cl e.
(2) Al i gn outl i ne mark on i nsi de of sl i di ng door to
rol l er arm bracket.
(3) I nstal l bol ts hol di ng l ower rol l er arm bracket to
sl i di ng door.
(4) I nstal l l ower rol l er arm.
(5) Remove l i fti ng devi ce.
(7) I nstal l access hol e pl ug.
SLIDING DOOR OUTSIDE LATCH RELEASE HANDLE
REMOVAL
(2) Remove sl i di ng door stop bumper.
(3) Remove watershi el d as necessary to access out-
si de rel ease handl e fasteners.
(5) Di sengage cl i p hol di ng outsi de door handl e
l i nkage to door handl e.
(6) Separate l i nkage from outsi de door handl e.
(7) Separate l i nkage from l atch/l ock control .
outer door panel (Fi g. 119).
INSTALLATION
(1) Posi ti on outsi de door handl e on vehi cl e.
(2) I nstal l nuts to hol d outsi de door handl e to
outer door panel .
(3) I nsert l i nkage i nto outsi de door handl e.
(4) Engage cl i p to hol d l i nkage to outsi de door
handl e.
(5) Engage ri ggi ng cam to l atch/l ock control mech-
ani sm.
(6) Move cl i p on l atch/l ock control to bottom of sl ot
and engage l i nkage to l atch/l ock control .
sary.
(8) I nstal l l atch/l ock cover.
(9) I nstal l watershi el d.
(10) I nstal l sl i di ng door stop bumper.
Fig. 116 Sliding Door Lower Roller Arm
Fig. 117 Sliding Door Roller Arm Channel
Fig. 118 Sliding Door Lower Roller Arm Bracket
Fig. 119 Sliding Door Outside Latch Release Handle
23 - 72 BODY NS
SLIDING DOOR REAR LATCH
REMOVAL
(2) Remove water shi el d as necessary.
(3) Open sl i di ng door to the ajar posi ti on.
(4) Di sengage cl i p hol di ng l i nkage to rear l atch.
(5) Remove screws hol di ng rear l atch to sl i di ng
door end frame (Fi g. 120).
(6) Remove sl i di ng door rear l atch from door
through rear access hol e.
INSTALLATION
NOTE: The screws attaching the rear latch to slid-
ing door end frame have locking patch on the
threads. Screws must be replaced during installa-
tion.
(1) Posi ti on sl i di ng door rear l atch on door through
rear access hol e.
(2) I nstal l screws to hol d rear l atch to sl i di ng door
end frame.
(3) Engage cl i p to hol d l i nkage to rear l atch.
sary.
SLIDING DOOR SILL PLATE
REMOVAL
(1) Di sengage hi dden cl i ps hol di ng si l l pl ate to
sl i di ng door openi ng si l l .
(2) Di sengage hooks hol di ng outsi de edge of si l l
pl ate to door si l l (Fi g. 121).
(3) Remove si l l pl ate from vehi cl e.
INSTALLATION
(2) Engage hooks to hol d outsi de edge of si l l pl ate
to door si l l .
(3) Al i gn gui de pi ns to hol es i n door si l l .
(4) Engage hi dden cl i ps to hol d si l l pl ate to sl i di ng
door openi ng si l l .
SLIDING DOOR STABILIZER
REMOVAL
(2) Remove screws hol di ng stabi l i zer to door end
frame (Fi g. 122).
(3) Remove stabi l i zer from vehi cl e.
INSTALLATION
(1) Pl ace stabi l i zer i n posi ti on on vehi cl e.
NOTE: Loose install screws first. Fit should be
snug but free to move when closing door to align to
body half stabilizer.
(2) I nstal l screws to hol d stabi l i zer to door end
frame.
(3) Open door and fi nal torque screws.
Fig. 120 Sliding Door Rear Latch
Fig. 121 Sliding Door Sill Plate
Fig. 122 Sliding Door Stabilizer
NS BODY 23 - 73
SLIDING DOOR STABILIZER SOCKET
REMOVAL
(2) Remove screws hol di ng stabi l i zer socket to
(3) Remove stabi l i zer socket from vehi cl e.
INSTALLATION
(1) Pl ace stabi l i zer socket i n posi ti on on vehi cl e.
(2) I nstal l screws to hol d stabi l i zer socket to B-pi l l ar.
(3) Cl ose sl i di ng door and veri fy operati on.
SLIDING DOOR STOP BUMPER
REMOVAL
(1) Remove center stop bumper tri m panel .
(2) Loosen screws hol di ng rear of stop bumper to
door i nner panel (Fi g. 124).
(3) Remove screw hol di ng front of stop bumper to
door i nner panel .
(4) Remove stop bumper from vehi cl e.
INSTALLATION
(1) Pl ace stop bumper i n posi ti on on vehi cl e.
(2) I nstal l screw to hol d front of stop bumper to
door i nner panel (Fi g. 124).
(3) Ti ghten screws to hol d rear of stop bumper to
door i nner panel .
(4) I nstal l tri m panel .
SLIDING DOOR TRIM PANEL
REMOVAL
(1) Remove sl i di ng door upper frame mol di ng.
(2) I f removi ng the l eft sl i di ng door tri m panel ,
remove screw from i nsi de ash recei ver bezel .
(3) Remove screws hol di ng tri m panel to i nner
door panel (Fi g. 126).
(4) Di sengage push-i n fasteners hol di ng tri m to
door panel around peri meter and upper edge of door
(Fi g. 125).
(5) Remove sl i di ng door tri m panel from vehi cl e.
INSTALLATION
(1) Pl ace sl i di ng door tri m panel i n posi ti on on
vehi cl e.
mati ng hol es i n the i nner door panel .
(3) Engage push-i n fasteners to hol d tri m to door
panel around peri meter and upper edge of door (Fi g.
125).
(4) I nstal l screws to hol d tri m panel to i nner door
panel .
Fig. 123 Sliding Door Stabilizer Socket
Fig. 124 Sliding Door Stop Bumper
Fig. 125 Sliding Door Trim Panel
23 - 74 BODY NS
(5) I f necessary, i nstal l screw from i nsi de ash
recei ver bezel on l eft sl i di ng door tri m panel .
(6) I nstal l sl i di ng door upper frame mol di ng.
SLIDING DOOR UPPER ROLLER
REMOVAL
(1) Open sl i di ng door, do not l atch open.
(2) Remove screw hol di ng upper stop bracket to
upper rol l er bracket (Fi g. 127).
(3) Remove stop bracket from vehi cl e.
(4) Pl ace a padded bl ock between the open sl i di ng
door and the roof rai l .
(5) Mark outl i ne of upper rol l er bracket on sl i di ng
door.
(6) Remove bol ts hol di ng upper rol l er to sl i di ng
door (Fi g. 128).
(7) Remove upper rol l er from door.
(8) Sl i de rol l er out of rear end of roof rai l channel .
(9) Remove upper rol l er from vehi cl e.
INSTALLATION
(1) Pl ace upper rol l er i n posi ti on on vehi cl e.
(2) Sl i de rol l er i nto rear end of roof rai l channel .
(3) Pl ace upper rol l er i n posi ti on on door.
(4) Al i gn outl i ne marks on sl i di ng door to upper
rol l er bracket
(5) I nstal l bol ts to hol d upper rol l er to sl i di ng door.
(6) Remove padded bl ock from between sl i di ng
door and roof rai l .
(7) Pl ace stop bracket i n posi ti on on vehi cl e.
(8) I nstal l screw to hol d upper stop bracket to
upper rol l er bracket.
Adjust as necessary.
SLIDING DOOR WEATHER-STRIP
REMOVAL
(2) Remove door openi ng si l l pl ate.
(3) Loosen B-pi l l ar tri m covers.
(4) Loosen quarter panel tri m panel s.
(5) From spl i ce at the bottom center of door open-
i ng, pul l weather-stri p from pi nch fl ange around door
openi ng.
INSTALLATION
STICK-ON BODY SIDE MOLDING
REMOVAL
Refer to (Fi g. 129), (Fi g. 130), (Fi g. 131), (Fi g. 132)
or (Fi g. 133) for proper l ocati on of fasteners hol di ng
the mol di ng to the wheel house l i p and rocker panel s.
(1) Warm the affected sti ck-on mol di ng and body
metal to approxi matel y 38C (100F) usi ng a sui tabl e
heat l amp or heat gun.
Fig. 126 Sliding Door Trim Panel Screws
Fig. 127 Sliding Door Upper Stop
Fig. 128 Sliding Door Upper Roller
NS BODY 23 - 75
(2) I f equi pped, remove pop-ri vets hol di ng mol di ng
edge to wheel house l i p.
(3) Pul l sti ck-on mol di ng from pai nted surface.
(4) Remove adhesi ve tape resi due from pai nted
surface of vehi cl e. Use a 3M Scotch-Bri te Mol di ng
Adhesi ve and Stri pe Removal Di sc, or equi val ent, to
cl ean adhesi ve resi due from pai nted surfaces. These
products are avai l abl e from automoti ve pai nt suppl i -
ers. Refer to i nstructi ons suppl i ed wi th the speci fi c
product for proper usage.
INSTALLATION
Refer to (Fi g. 129), (Fi g. 130), (Fi g. 131), (Fi g. 132)
or (Fi g. 133) for proper l ocati on of fasteners to hol d
the mol di ng to the wheel house l i p and rocker panel s.
(1) I f mol di ng i s to be reused;
(a) Remove tape resi due from mol di ng.
(b) Cl ean back of mol di ng wi th Mopar Super
Kl een, or equi val ent.
(c) Wi pe mol di ng dry wi th l i nt free cl oth.
(d) Appl y a si ngl e coat of Mopar TPO Mol di ng
Prep to tape si de of mol di ng and al l ow to dry thor-
oughl y.
(e) Appl y new body si de mol di ng (two si ded
adhesi ve) tape to back of mol di ng.
(2) Cl ean body surface wi th Mopar Super Kl een,
or equi val ent. Wi pe surface dry wi th l i nt free cl oth.
(3) Remove protecti ve cover from tape on back of
mol di ng.
(4) Appl y mol di ng to body from front to rear,
i nserti ng l ocator pi ns i nto hol e i n body panel .
(5) Usi ng a rol l er tool , rol l mol di ng onto body
panel wi th enough force to assure adhesi on. Do not
appl y excessi ve force, or damage to body panel s may
resul t.
(6) I nstal l pop-ri vets to hol d mol di ng edge to
wheel house l i p, i f necessary.
SUN VISOR
Al l vehi cl es wi th dri ver and passenger si de ai rbags
must have a col ored coded fi ve Bul l et poi nt ai rbag
warni ng l abel appl i ed to the sun vi sor, veri fy l abel
avai l abi l i ty and ensure the l abel i s i nstal l ed.
REMOVAL
(1) Di sengage sun vi sor from center support.
(2) Remove screws attachi ng sun vi sor to roof
header (Fi g. 134).
(3) Remove sun vi sor from roof.
(4) I f equi pped, di sconnect i l l umi nated vani ty mi r-
ror wi re connector from body harness.
(5) Remove sun vi sor from vehi cl e.
Fig. 129 Body Side Moldings Base
23 - 76 BODY NS
Fig. 130 Body Side Moldings Highline
Fig. 131 Body Side Moldings Premium
NS BODY 23 - 77
INSTALLATION
(1) Pl ace sun vi sor i n posi ti on on vehi cl e.
(2) Connect i l l umi nated vani ty mi rror wi re connec-
tor i nto body harness.
(3) Pl ace sun vi sor i n posi ti on on roof.
(4) I nstal l screws to hol d sun vi sor to roof header
(Fi g. 134).
(5) Engage sun vi sor i nto center support.
SUN VISOR SUPPORT
REMOVAL
(1) Di sengage sun vi sor from support.
(2) Remove screw hol di ng support to roof header
(Fi g. 135).
(3) Remove sun vi sor support from vehi cl e.
INSTALLATION
(1) Pl ace sun vi sor support i n posi ti on on vehi cl e.
(2) I nstal l screw hol di ng support to roof header
(Fi g. 135).
(3) Engage sun vi sor i nto support.
UPPER B-PILLAR TRIM COVER
REMOVAL
(1) Remove bol t hol di ng l ower seat bel t anchor to
fl oor.
(2) Lower shoul der bel t hei ght adjuster to the bot-
tom of travel .
(3) Remove shoul der bel t turni ng l oop from hei ght
adjuster.
(4) Usi ng Snap-on pryi ng tool (A179A), or equi v-
al ent, remove shoul der bel t hei ght adjuster knob.
(5) Remove shoul der bel t bezel from tri m cover.
(6) Remove screw hol di ng tri m cover to B-pi l l ar
from i nsi de bezel cavi ty.
(7) Di sengage hi dden cl i ps hol di ng tri m cover to
B-pi l l ar.
(8) Remove B-pi l l ar tri m cover from vehi cl e (Fi g.
136).
Fig. 132 Body Side Moldings Luxury
23 - 78 BODY NS
INSTALLATION
(1) I nsert seat bel t through B-pi l l ar tri m and web
gui de.
(2) Pl ace B-pi l l ar tri m cover i n posi ti on on vehi cl e.
(3) Engage hi dden cl i ps to hol d tri m cover to B-pi l -
l ar.
(4) I nstal l screw to hol d tri m cover to B-pi l l ar
i nsi de bezel cavi ty.
(5) I nstal l shoul der bel t bezel i nto tri m cover.
(6) I nstal l hei ght adjuster knob.
(7) I nstal l shoul der bel t turni ng l oop onto hei ght
adjuster.
(8) Pl ace seat anchor i n posi ti on on fl oor so web-
bi ng i s poi nted rearward and sl i ghtl y outboard.
(9) I nstal l bol t to hol d l ower seat bel t anchor to
fl oor. Ti ghten seat bel t bol ts to 39 Nm (29 i n. l bs.)
torque.
Fig. 133 Body Side Moldings with Applique
Fig. 134 Sun Visor
Fig. 135 Sun Visor Support
NS BODY 23 - 79
UPPER C-PILLAR TRIM
REMOVAL
(2) Remove seat bel t turni ng l oop from hei ght
adjuster.
(3) Remove screw hol di ng C-pi l l ar tri m panel to
C-pi l l ar on ri ght si de of SWB vehi cl e.
(4) Di sengage hi dden cl i ps hol di ng tri m to upper
C-pi l l ar.
(5) Remove upper C-pi l l ar tri m from vehi cl e.
INSTALLATION
(1) Pl ace upper C-pi l l ar tri m i n posi ti on on vehi cl e.
(2) Engage hi dden cl i ps to hol d tri m to upper
C-pi l l ar.
(3) I nstal l screw to hol d C-pi l l ar tri m panel to
C-pi l l ar on ri ght si de of SWB vehi cl e.
(4) I nstal l seat bel t turni ng l oop onto hei ght
adjuster. Ti ghten al l seat bel t bol ts to 39 Nm (29 i n.
l bs.) torque.
ADJ USTMENTS
SLIDING DOOR ADJUSTMENTS
PRELIMINARY CHECKS
(1) Cl ose sl i di ng door, vi sual l y checki ng C-post
stri ker al i gnment entry i nto l atch. Stri ker at thi s
poi nt must not affect al i gnment.
(2) On vehi cl es wi th l eft sl i di ng doors, check the
fuel door bl ocker stri ker entry i nto l atch. Stri ker at
thi s poi nt must not affect al i gnment.
(3) Check C-post and B-post for door to aperture
gaps and door to door gaps. Al l gaps shoul d be 5 mm
1 mm.
(4) Check door for hei ght usi ng character l i nes as a
reference. Al so check roof contour as a control l i ng factor.
UP/DOWN ADJ USTMENT
(1) Vi sual l y i nspect the sl i di ng door for fi tti ng l ow
at the rear of the door by checki ng the al i gnment of
the bel t l i ne of the door to quarter panel .
(2) Ful l y open the sl i di ng door.
(3) Veri fy that al l center hi nge bol ts are ti ght.
(4) Adjust the rear of the sl i di ng door up by turn-
i ng the center hi nge bol t cl ockwi se (Fi g. 137).
(5) Cl ose the door and check the sl i di ng door al i gn-
ment.
(6) Readjust the center hi nge i f necessary to obtai n
al i gnment between the bel t l i ne of the sl i di ng door
and quarter panel .
(7) Ful l y open door and appl y thread l ock nut onto
the center hi nge bol t. Ti ghten nut unti l ti l l i t butts
up agai nst the wel ded nut on the center hi nge.
Ti ghten nut to 15 Nm (130 i n. l bs.). I t may be nec-
essary to hol d the center hi nge bol t to prevent i t
from turni ng whi l e ti ghteni ng nut.
(8) Veri fy al i gnment. Re-adjust as necessary.
FORE/AFT ADJ USTMENT
(1) Check hei ght of sl i di ng door at the B-post and
C-post to determi ne whi ch area i s contri buti ng the
greatest to the i ncorrect gaps.
(2) I f the sl i di ng door i s hi gh at the C-post;
(a) Open the door to mi d-poi nt of travel .
Fig. 136 Upper B-pillar Trim Cover
Fig. 137 Sliding Door Center Hinge
23 - 80 BODY NS
(b) Mark outl i ne of center hi nge on sl i di ng door
to assi st i n maki ng adjustments.
(c) Loosen center hi nge bol ts (Fi g. 137).
(d) Move hi nge fore or aft to posi ti on the sl i di ng
door i nto the correct l ocati on.
(e) Ti ghten center hi nge bol ts.
(f) Veri fy al i gnment. Re-adjust as necessary.
(3) I f the sl i di ng door i s l ow at the B-post;
(a) Remove access pl ug i n the sl i di ng door tri m
panel .
(b) Open the door to mi d-poi nt of travel .
(c) Mark outl i ne of l ower rol l er arm bracket on
sl i di ng door to assi st i n maki ng adjustments.
(d) Loosen l ower rol l er arm bracket bol ts (Fi g.
138).
(e) Move hi nge downward to rai se the door.
(f) Ti ghten l ower rol l er arm bracket bol ts.
(g) Veri fy al i gnment. Re-adjust as necessary.
(4) I f the sl i di ng door i s l ow at the C-post;
(a) Open the door to mi d-poi nt of travel .
(b) Mark outl i ne of center hi nge on sl i di ng door
(c) Adjust the adjustment bol t up or down to
move the door posi ti on. (Fi g. 137).
(d) Move hi nge downward to rai se the door.
(e) Ti ghten center hi nge bol ts.
(f) Veri fy al i gnment. Re-adjust as necessary.
(5) I f the sl i di ng door i s hi gh at the B-post;
(a) Remove access pl ug i n the sl i di ng door tri m
panel .
(b) Open the door to mi d-poi nt of travel .
(c) Mark outl i ne of l ower rol l er arm bracket on
sl i di ng door to assi st i n maki ng adjustments.
(d) Loosen l ower rol l er arm bracket bol ts (Fi g.
138).
(e) Move hi nge upward to rai se the door.
(f) Ti ghten l ower rol l er arm bracket bol ts.
SEAL COMPRESSION
(1) Check seal compressi on at top and bottom of
B-post seal .
(2) Adjust seal compressi on at the top of the
B-post seal ;
(a) Open door to mi d-poi nt of travel .
(b) Mark outl i ne of upper rol l er arm on bracket
(c) Loosen bol ts hol di ng upper rol l er arm to
bracket (Fi g. 139)
(d) Decrease the l ength of the upper rol l er arm
to i ncrease seal compressi on.
(e) I ncrease the l ength of the upper rol l er arm to
decrease seal compressi on.
(f) Ti ghten al l upper rol l er arm bol ts.
(g) Veri fy door al i gnment. Re-adjust as neces-
sary.
(3) Adjust seal compressi on at the bottom of B-post
seal .
(a) Open door to mi d-poi nt of travel .
(b) Mark outl i ne of l ower rol l er arm on l ower
rol l er arm bracket to assi st i n maki ng adjustments.
(c) Loosen bol ts hol di ng l ower rol l er arm to
l ower rol l er arm bracket.
(d) Pi vot l ower rol l er arm toward center of vehi -
cl e to decrease seal compressi on.
(e) Pi vot l ower rol l er arm outward to i ncrease
seal compressi on.
(f) Ti ghten l ower rol l er arm bol ts.
Fig. 138 Sliding Door Lower Roller Arm Bracket
Fig. 139 Sliding Door Upper Roller Arm
NS BODY 23 - 81
NOTE: Adjusting seal compression at the B-post
can affect door flushness the C-post.
STABILIZER ADJ USTMENT
(2) Loosen bol ts hol di ng stabi l i zers to sl i di ng door
enough that the stabi l i zers can move wi th some
effort.
(3) Cl ose and then reopen sl i di ng door.
(4) Ti ghten al l bol ts.
Fig. 140 Sliding Door Lower Roller Arm
23 - 82 BODY NS
BODY
CONTENTS
page page
BODY COMPONENT SERVICE . . . . . . . . . . . . . . . 3 SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
SEATS
INDEX
page page
BENCH SEAT BACK COVER . . . . . . . . . . . . . . . . 2
HEAD RESTRAINT ESCUTCHEON . . . . . . . . . . . 1
HEAD RESTRAINT SLEEVE . . . . . . . . . . . . . . . . . 2
HEAD RESTRAINT . . . . . . . . . . . . . . . . . . . . . . . . 1
HEAD RESTRAINT
REMOVAL
(3) Pul l head restrai nt from top of seat back.
INSTALLATION
(1) Posi ti on head restrai nt to seat.
seat back.
(3) I nsert head restrai nt i nto sl eeves at top of seat
back.
HEAD RESTRAINT ESCUTCHEON
REMOVAL
(1) Remove head restrai nt from seat.
(2) Remove escutcheon from head restrai nt sl eeve
(Fi g. 2).
(3) Remove head restrai nt retai ner from sl eeve.
(4) Separate escutcheon and retai ner from vehi cl e.
INSTALLATION
(1) Posi ti on escutcheon and retai ner to seat.
(2) I nstal l retai ner to sl eeve.
(3) I nstal l escutcheon to sl eeve.
(4) I nstal l head restrai nt to seat.
Fig. 1 Head RestraintBucket Seat
NS/GS BODY 23 - 1
HEAD RESTRAINT SLEEVE
REMOVAL
(1) Remove head restrai nt.
(2) Di sengage cl osure hol di ng bottom of tri m cover
together.
(3) Reach under tri m cover through openi ng at
bottom of seat back.
(4) Pi nch retai ner barbs on mi ddl e of head
restrai nt sl eeve together (Fi g. 3).
(5) Pul l head restrai nt sl eeve upward and out the
top of the seat back frame gui de tube.
INSTALLATION
(1) I nsert head restrai nt sl eeve i nto gui de tube at
top of seat back.
(2) Al i gn l ocator ri b to l ocator ri b notch i n gui de
tube (Fi g. 4).
(3) Push head restrai nt sl eeve downward unti l
retai ner cl i cks i nto l ock posi ti on.
(4) Engage cl osure to hol d bottom of tri m cover
together.
(5) I nstal l head restrai nt.
BENCH SEAT BACK COVER
REMOVAL
(1) Remove screws hol di ng the bottom of the bench
seat back cover to the seat frame (Fi g. 5).
(2) Di sengage hooks hol di ng top of seat back cover
to seat back frame.
(3) Separate seat back cover from seat.
INSTALLATION
(1) Pl ace seat back cover i n posi ti on on seat.
(2) Engage hooks to hol d top of seat back cover to
seat back frame.
(3) I nstal l screws to hol d bottom of bench seat
back cover to seat frame.
Fig. 2 Head Restraint Escutcheon and Retainer
Fig. 3 Head Restraint Sleeve Removal
Fig. 4 Head Restraint Sleeve Installation
Fig. 5 Bench Seat Back Cover
23 - 2 BODY NS/GS
BODY COMPONENT SERVICE
INDEX
page page
GEARSHIFT CONSOLE . . . . . . . . . . . . . . . . . . . . 3
LIFTGATE CHMSL ACCESS PANEL . . . . . . . . . . . 3
GEARSHIFT CONSOLE
REMOVAL
(1) Li ft the parki ng brake l ever to the ful l up posi -
ti on (Fi g. 1).
(2) Careful l y pul l the base of the gearshi ft boot off
the top of the gearshi ft consol e.
(3) Remove the four (4) screws from the top of the
gearshi ft consol e (Fi g. 2).
(4) Ti l t the gearshi ft boot and careful l y push the
boot through the openi ng i n the gearshi ft consol e.
(5) Separate consol e from vehi cl e.
INSTALLATION
(1) Ti l t the gearshi ft boot and careful l y push the
boot through the gearshi ft consol e.
(2) I nstal l screws to hol d gearshi ft consol e to gear-
shi ft mechani sm.
(3) I nstal l gearshi ft boot and careful l y push the
cl i ps i nto the three (3) sl ots i n the gearshi ft consol e.
LIFTGATE CHMSL ACCESS PANEL
REMOVAL
(1) Usi ng a tri m sti ck (C-4755), di sengage cl i p
hol di ng CHMSL access panel to l i ftgate tri m panel
(Fi g. 3).
(2) Di sengage hooks on CHMSL access cover from
(3) Separate access panel from vehi cl e.
Fig. 1 Console, Parking Brake Lever, and Gearshift
Boot
Fig. 2 Gearshift Console and Boot Removal
NS/GS BODY 23 - 3
INSTALLATION
(1) Pl ace access panel i n posi ti on on vehi cl e.
(2) Engage hooks on CHMSL access cover to l i ft-
gate tri m panel .
(3) Engage cl i p to hol d CHMSL access panel to
Fig. 3 CHMSL Access Panel
23 - 4 BODY NS/GS
HEATING AND AIR CONDITIONING
CONTENTS
page page
FRONT HEATING AND AIR CONDITIONING
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
REAR HEATING AND AIR CONDITIONING
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
FRONT HEATING AND AIR CONDITIONING SYSTEM
INDEX
page page
GENERAL INFORMATION
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . 2
SAFETY PRECAUTIONS AND WARNINGS . . . . . . 2
A/C PRESSURE TRANSDUCER . . . . . . . . . . . . . . 2
A/C SERVICE PORTS . . . . . . . . . . . . . . . . . . . . . 2
AIR DISTRIBUTION DUCTS . . . . . . . . . . . . . . . . . 2
COMPRESSOR HIGH-PRESSURE RELIEF
VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
CONDENSATE DRAIN . . . . . . . . . . . . . . . . . . . . . 3
ENGINE COOLING SYSTEM REQUIREMENTS . . 3
EVAPORATOR PROBE . . . . . . . . . . . . . . . . . . . . . 3
HANDLING TUBING AND FITTINGS . . . . . . . . . . . 3
HVAC CONTROL MODULE . . . . . . . . . . . . . . . . . 4
REAR BLOWER SPEED SWITCH . . . . . . . . . . . . 3
SIDE DOOR HEATER A/C OUTLETS . . . . . . . . . . 4
SIDE WINDOW DEMISTER . . . . . . . . . . . . . . . . . 4
SYSTEM AIRFLOW . . . . . . . . . . . . . . . . . . . . . . . 4
SYSTEM OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . 5
A/C PERFORMANCE TEST . . . . . . . . . . . . . . . . 12
A/C PRESSURE TRANSDUCER . . . . . . . . . . . . . 12
ACTUATOR CALIBRATION/DIAGNOSTICS AND
COOLDOWN TEST . . . . . . . . . . . . . . . . . . . . . . 6
BLOWER MOTOR AND WHEEL ASSEMBLY . . . . 13
COMPRESSOR CLUTCH/COIL . . . . . . . . . . . . . . 13
COMPRESSOR NOISE DIAGNOSIS . . . . . . . . . . 13
EXPANSION VALVE . . . . . . . . . . . . . . . . . . . . . . 13
HEATER PERFORMANCE TEST . . . . . . . . . . . . 15
HVAC CONTROL DIAGNOSTIC CONDITIONS . . . 9
SYSTEM CHARGE LEVEL TEST . . . . . . . . . . . . 16
SERVICE PROCEDURES
CHARGING REFRIGERANT SYSTEM . . . . . . . . 17
EVACUATING REFRIGERANT SYSTEM . . . . . . . 18
R-134a REFRIGERANT . . . . . . . . . . . . . . . . . . . 16
STICKING HVAC CONTROL MODULE PUSH
BUTTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
SYSTEM LEAK CHECKING . . . . . . . . . . . . . . . . 19
THERMOCOUPLE PROBE . . . . . . . . . . . . . . . . . 19
A/C PRESSURE TRANSDUCER . . . . . . . . . . . . . 20
A/C SERVICE PORTS . . . . . . . . . . . . . . . . . . . . 20
BLEND-AIR DOOR ACTUATOR . . . . . . . . . . . . . 20
BLOWER MOTOR AND WHEEL ASSEMBLY . . . . 21
BLOWER MOTOR RESISTOR BLOCK . . . . . . . . 21
BLOWER MOTOR WHEEL . . . . . . . . . . . . . . . . . 22
COMPRESSOR CLUTCH/COIL . . . . . . . . . . . . . . 23
COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . 23
CONDENSER ASSEMBLY . . . . . . . . . . . . . . . . . 25
DISCHARGE LINE . . . . . . . . . . . . . . . . . . . . . . . 26
EVAPORATOR PROBE . . . . . . . . . . . . . . . . . . . . 27
EXPANSION VALVE . . . . . . . . . . . . . . . . . . . . . . 28
FILTER-DRIER ASSEMBLY . . . . . . . . . . . . . . . . . 28
HEATER A/C UNIT HOUSING . . . . . . . . . . . . . . . 29
HEATER CORE . . . . . . . . . . . . . . . . . . . . . . . . . 30
HEATER HOSES . . . . . . . . . . . . . . . . . . . . . . . . 31
LIQUID LINE . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
MODE DOOR ACTUATOR . . . . . . . . . . . . . . . . . 32
RECIRC DOOR ACTUATOR . . . . . . . . . . . . . . . . 34
SIDE WINDOW DEMISTER DUCTS . . . . . . . . . . 33
SUCTION LINE . . . . . . . . . . . . . . . . . . . . . . . . . . 33
HEATER A/C UNIT RECONDITION . . . . . . . . . . . 34
NS HEATING AND AIR CONDITIONING 24 - 1
GENERAL INFORMATION
INTRODUCTION
Both the heater and the heater/ai r condi ti oni ng
systems share many of the same components. Thi s
group wi l l deal wi th both systems together when
component functi on i s common, and separatel y when
they are not.
For proper operati on of the i nstrument panel con-
trol s, refer to the Owners Manual provi ded wi th the
vehi cl e.
Al l vehi cl es are equi pped wi th a common A/C-
heater uni t housi ng assembl y. When the vehi cl e has
onl y a heater system, the evaporator and reci rcul at-
i ng ai r door are omi tted.
An opti onal zone control HVAC uni t i s avai l abl e.
Thi s uni t has dual bl end-ai r doors that can be regu-
l ated i ndependentl y of each other. The temperature
setti ng can be di fferent from dri vers si de to passen-
ger si de. There i s al so a rear (aux.) heati ng and A/C
system avai l abl e when the vehi cl e i s equi pped wi th
zone control .
WARNING: WEAR EYE PROTECTION WHEN SER-
VICING THE AIR CONDITIONING REFRIGERANT
SYSTEM. SERIOUS EYE INJURY CAN RESULT
FROM EYE CONTACT WITH REFRIGERANT. IF EYE
CONTACT IS MADE, SEEK MEDICAL ATTENTION
IMMEDIATELY.
DO NOT EXPOSE REFRIGERANT TO OPEN
FLAME. POISONOUS GAS IS CREATED WHEN
REFRIGERANT IS BURNED. AN ELECTRONIC TYPE
LEAK DETECTOR IS RECOMMENDED.
LARGE AMOUNTS OF REFRIGERANT RELEASED
IN A CLOSED WORK AREA WILL DISPLACE THE
OXYGEN AND CAUSE SUFFOCATION.
THE EVAPORATION RATE OF REFRIGERANT AT
AVERAGE TEMPERATURE AND ALTITUDE IS
EXTREMELY HIGH. AS A RESULT, ANYTHING THAT
COMES IN CONTACT WITH THE REFRIGERANT
WILL FREEZE. ALWAYS PROTECT SKIN OR DELI-
CATE OBJECTS FROM DIRECT CONTACT WITH
REFRIGERANT. R-134a SERVICE EQUIPMENT OR
VEHICLE A/C SYSTEM SHOULD NOT BE PRES-
SURE TESTED OR LEAK TESTED WITH COM-
PRESSED AIR.
SOME MIXTURES OF AIR and R-134a HAVE BEEN
SHOWN TO BE COMBUSTIBLE AT ELEVATED
PRESSURES. THESE MIXTURES ARE POTENTIALLY
DANGEROUS AND MAY RESULT IN FIRE OR
EXPLOSION CAUSING INJURY OR PROPERTY
DAMAGE.
ANTIFREEZE IS AN ETHYLENE GLYCOL BASE
COOLANT AND IS HARMFUL IF SWALLOWED OR
INHALED. SEEK MEDICAL ATTENTION IMMEDI-
ATELY IF SWALLOWED OR INHALED. DO NOT
STORE IN OPEN OR UNMARKED CONTAINERS.
WASH SKIN AND CLOTHING THOROUGHLY AFTER
COMING IN CONTACT WITH ETHYLENE GLYCOL.
KEEP OUT OF REACH OF CHILDREN AND PETS.
DO NOT OPEN A COOLING SYSTEM WHEN THE
ENGINE IS AT RUNNING TEMPERATURE. PER-
CAUTION: The engine cooling system is designed
to develop internal pressure of 97 to 123 kPa (14 to
18 psi). Allow the vehicle to cool a minimum of 15
minutes before opening the cooling system. Refer
to Group 7, Cooling System.
AIR DISTRIBUTION DUCTS
The ai r di stri buti on ducts for the A/C, Heater,
Defroster, and Second Seati ng Ai r Di stri buti on are
not servi ceabl e i n vehi cl e. The procedures for servi ce
of these ducts are covered i n Group 8E, I nstrument
Panel and Gauges.
The onl y ducts that are servi ceabl e i n the vehi cl e
are the si de wi ndow demi ster ducts and the ducts
that feed the front door outl ets for the fi rst rear pas-
senger(s) seati ng. To servi ce the door ducts refer to
Group 23, Body.
A/C PRESSURE TRANSDUCER
The A/C Pressure Transducer (Fi g. 1) moni tors the
refri gerant gas pressure on the hi gh si de of the sys-
tem. The transducer i s l ocated on the l i qui d l i ne. The
pressure transducer turns off the vol tage to the com-
pressor cl utch coi l when refri gerant gas pressure
drops to l evel s that coul d damage the compressor.
The transducer al so i s used to adjust condenser fan
speeds and wi l l turn off compressor at hi gh refri ger-
ant pressures. The pressure transducer i s a seal ed
factory cal i brated uni t. I t must be repl aced i f defec-
ti ve. O-ri ng repl acement i s requi red whenever the
pressure transducer i s servi ced. Be sure to use the
O-ri ng speci fi ed for the transducer.
A/C SERVICE PORTS
The A/C servi ce port val ve cores are l ocated wi thi n
the A/C l i nes (Fi g. 2). The Hi gh Si de (Di scharge)
val ve servi ce port i s l ocated on the l i qui d l i ne near
the ri ght frame rai l . The Low Si de (Sucti on) val ve
servi ce port i s l ocated on the sucti on l i ne near the
compressor.
24 - 2 HEATING AND AIR CONDITIONING NS
The Hi gh Si de servi ce port i s a two pi ece port and
i s servi ceabl e. The Low Si de servi ce port i s not ser-
vi ceabl e, the sucti on l i ne woul d have to be repl aced.
REAR BLOWER SPEED SWITCH
The rear bl ower speed swi tch control s the rear
bl ower wi th the choi ce of l ow and hi gh speeds. When
the swi tch i s on i t al l ows the bl ower speed swi tch
l ocated on the rear headl i ner to control rear bl ower
speed. Thi s swi tch wi l l overri de the rear headl i ner
bl ower swi tch. For operati on i nstructi ons refer to the
Owners Manual . The rear bl ower speed swi tch i s
servi ced separatel y from the A/C control modul e. For
servi ce procedures, refer to Group 8E, I nstrument
Panel And Gauges.
COMPRESSOR HIGH-PRESSURE RELIEF VALVE
The Hi gh Pressure Rel i ef Val ve prevents damage
to the ai r condi ti oni ng system i f excessi ve pressure
devel ops. Excessi ve pressure can be caused by con-
denser ai r fl ow bl ockage, refri gerant overcharge, or
ai r and moi sture i n the system.
The hi gh pressure rel i ef val ve vents onl y a smal l
amount of refri gerant necessary to reduce system
pressure and then reseats i tsel f. The majori ty of the
refri gerant i s conserved i n the system. The val ve i s
cal i brated to vent at a pressure of 3450 to 4140 kPa
(500 to 600 psi ). I f a val ve has vented a smal l
amount of refri gerant, i t does not necessari l y mean
the val ve i s defecti ve.
The Hi gh Pressure Rel i ef Val ve i s l ocated on the
compressor mani fol d at the di scharge passage.
NOTE: Special effort must be used to keep all
R-134a system components moisture-free. Moisture
in the oil is very difficult to remove and will cause a
reliability problem with the compressor.
CONDENSATE DRAIN
Condensati on from the evaporator housi ng i s
drai ned through the dash panel and on to the
ground. Thi s drai n must be kept open to prevent
water from col l ecti ng i n the bottom of the housi ng.
I f the drai n i s bl ocked condensate cannot drai n,
causi ng water to back up and spi l l i nto the passenger
compartment. I t i s normal to see condensate drai n-
age bel ow the vehi cl e.
ENGINE COOLING SYSTEM REQUIREMENTS
To mai ntai n ampl e temperature l evel s from the
heati ng-A/C system, the cool i ng system must be i n
proper worki ng order. Refer to Group 0, Lubri cati on
and Mai ntenance or Group 7, Cool i ng System of thi s
manual .
The use of a bug screen i s not recommended. Any
obstructi ons forward of the condenser can reduce the
effecti veness of the ai r condi ti oni ng system.
EVAPORATOR PROBE
The Evaporator probe i s l ocated on the HVAC. The
probe prevents evaporator freeze-up by si gnal i ng the
Powertrai n Control Modul e to cycl e the compressor
ON and OFF. The probe moni tors the temperature of
the refri gerant after expansi on.
The evaporator probe i s i nserted i nto the evapora-
tor between the coi l s. The probe i s a seal ed uni t and
cannot be adjusted or repai red. I t must be repl aced i f
found defecti ve.
HANDLING TUBING AND FITTINGS
Ki nks i n the refri gerant tubi ng or sharp bends i n
the refri gerant hose l i nes wi l l greatl y reduce the
capaci ty of the enti re system. Hi gh pressures are pro-
duced i n the system when i t i s operati ng. Extreme
care must be exerci sed to make sure that al l connec-
ti ons are pressure ti ght. Di rt and moi sture can enter
the system when i t i s opened for repai r or repl ace-
ment of l i nes or components. The refri gerant oi l wi l l
Fig. 1 A/C Pressure Transducer
Fig. 2 Valve Service Ports
absorb moi sture readi l y out of the ai r. Thi s moi sture
wi l l convert i nto aci ds wi thi n a cl osed system.
CAUTION: The system must be completely empty
before opening any fitting or connection in the
refrigeration system. Open fittings with caution
even after the system has been emptied. If any
pressure is noticed as a fitting is loosened,
retighten fitting and evacuate the system again.
A good rule for the flexible hose lines is to keep
the radius of all bends at least 10 times the diame-
ter of the hose. Sharper bends will reduce the flow
of refrigerant. The flexible hose lines should be
routed so they are at least 3 inches (80 mm) from
the exhaust manifold. Inspect all flexible hose lines
to make sure they are in good condition and prop-
erly routed.
The use of correct wrenches when making con-
nections is very important. Improper wrenches or
improper use of wrenches can damage the fittings.
The internal parts of the A/C system will remain
stable as long as moisture-free refrigerant and
refrigerant oil is used. Abnormal amounts of dirt,
moisture or air can upset the chemical stability.
This may cause operational troubles or even seri-
ous damage if present in more than very small
quantities.
When opening a refrigeration system, have every-
thing you will need to repair the system ready. This
will minimize the amount of time the system must
be opened. Cap or plug all lines and fittings as
soon as they are opened. This will help prevent the
entrance of dirt and moisture. All new lines and
components should be capped or sealed until they
are ready to be used.
All tools, including the refrigerant dispensing
manifold, the manifold gauge set, and test hoses
should be kept clean and dry.
HVAC CONTROL MODULE
The HVAC control modul e regul ates the operati on
of the vari ous actuator motors. The actuator motors
are used to move the mode, bl end- ai r, and RECI RC.
doors (Fi g. 3).
The control modul e i s i ncl uded i n the A/C control
head l ocated on the i nstrument panel . The control
head i ncl udes the bl ower speed swi tch, rear wi per
and washer operati on, front & rear wi ndow defogger,
reci rcul ati on door operati on, and A/C compressor
operati on i f equi pped. Refer to Group 8E, I nstrument
Panel and Systems for servi ce procedures.
NOTE: The RECIRC. function on the HVAC control
module automatically defaults to the OFF position
after a ignition key cycle. To reactivate the RECIRC.
function, the RECIRC. button must be repressed
The rear bl ower speed swi tch i s servi ced separatel y
from the control head.
SIDE DOOR HEATER A/C OUTLETS
The dri vers and passenger si de doors have suppl e-
mental ai r outl ets and duct work. The ai r i s chan-
nel ed from the i nstrument panel to the door duct and
ei ther to the l ower fl oor or upper door outl ets (Fi g.
4). The ai r can be adjusted to bl ow on the fi rst rear
passenger seat(s).
SIDE WINDOW DEMISTER
The si de wi ndow demi sters di rect ai r from the
heater assembl y. The outl ets are l ocated on the top
forward corners of the front door panel s (Fi g. 5). The
demi sters operate when the control mode sel ector i s
on FLOOR, MI X or DEFROST setti ng.
SYSTEM AIRFLOW
The system pul l s outsi de (ambi ent) ai r through the
cowl openi ng at the base of the wi ndshi el d. Then i t
goes i nto the pl enum chamber above the heaterA/C
Fig. 3 HVAC Control Module
Fig. 4 Door Outlets
uni t housi ng. On ai r condi ti oned vehi cl es, the ai r
passes through the evaporator. At thi s poi nt the ai r
fl ow can be di rected ei ther through or around the
heater core. Thi s i s done by adjusti ng the bl end- ai r
door wi th the TEMP control on the control head. An
opti onal zone control HVAC control modul e i s avai l -
abl e. Thi s uni t has dual bl end-ai r doors that can be
regul ated i ndependentl y of each other. The tempera-
ture setti ng can be di fferent from dri vers si de to pas-
senger si de. After the ai r passes the bl end-ai r door(s),
the ai r fl ow can then be di rected from the Panel ,
Fl oor, and Defrost outl ets. Ai r fl ow vel oci ty can be
adjusted wi th the bl ower speed sel ector swi tch on the
control head.
Ambi ent ai r i ntake can be shut off by cl osi ng the
reci rcul ati ng ai r door. Thi s wi l l reci rcul ate the ai r
that i s al ready i nsi de the vehi cl e. Thi s i s done by
depressi ng the Reci rc. button on the control head. On
ai r condi ti oned vehi cl es, movi ng the control to Mi x or
Defrost depresses the A/C button and wi l l engage the
compressor. Thi s wi l l send refri gerant through the
evaporator, and remove heat and humi di ty from the
ai r before i t goes through the heater core.
CAUTION: In cold weather, use of the Recirculation
mode may lead to excessive window fogging. The
Recirculation mode is automatically deactivated in
Mix and Defrost modes to improve window clearing
operation.
SYSTEM OIL LEVEL
I t i s i mportant to have the correct amount of oi l i n
the A/C system to ensure proper l ubri cati on of the
compressor. Too l i ttl e oi l wi l l resul t i n damage to the
compressor. Too much oi l wi l l reduce the cool i ng
capaci ty of the system and consequentl y resul t i n
hi gher di scharge ai r temperatures.
NOTE: The oil used in the compressor is ND8 PAG
R134a refrigerant oil. Only refrigerant oil of the
same type should be used to service the system.
Do not use any other oil. The oil container should
be kept tightly capped until it is ready for use.
Tightly cap afterwards to prevent contamination
from dirt and moisture. Refrigerant oil will quickly
absorb any moisture it comes in contact with. Spe-
cial effort must be used to keep all R-134a system
components moisture-free. Moisture in the oil is
very difficult to remove and will cause a reliability
problem with the compressor.
I t wi l l not be necessary to check oi l l evel i n the
compressor or to add oi l unl ess there has been an oi l
l oss. Oi l l oss at a l eak poi nt wi l l be evi dent by the
presence of a wet, shi ny surface around the l eak.
REFRIGERANT OIL LEVEL CHECK
When an ai r condi ti oni ng system i s fi rst assem-
bl ed, al l components (except the compressor) are
refri gerant oi l free. After the system has been
charged wi th R134a refri gerant and operated, the oi l
i n the compressor i s di spersed through the l i nes and
components. The evaporator, condenser, and fi l ter-
dri er wi l l retai n a si gni fi cant amount of oi l , refer to
the Refri gerant Oi l Capaci ti es chart. When a compo-
nent i s repl aced, the speci fi ed amount of refri gerant
oi l must be added. When the compressor i s repl aced,
the amount of oi l that i s retai ned i n the rest of the
system must be drai ned from the repl acement com-
pressor. When a l i ne or component has ruptured and
oi l has escaped, the compressor shoul d be removed
and drai ned. The fi l ter-dri er must be repl aced al ong
wi th the ruptured part. The oi l capaci ty of the sys-
tem, mi nus the amount of oi l sti l l i n the remai ni ng
components, can be measured and poured i nto the
sucti on port of the compressor.
Exampl e: On a dual system the evaporator retai ns
60 ml (2 oz). The condenser retai ns 30 ml (1 oz) of
oi l , and system capaci ty may be 220 ml (7.40 oz) of
oi l .
220 ml mi nus 90 ml = 130 ml (4.40 oz).
Fig. 5 Demister Inlet
CAUTION: The refrigerant oil used in a R-134a A/C
system is unique. Use only oils which were
designed to work with R-134a refrigerant. The oil
designated for this vehicle is ND8 PAG (polyalka-
lene glycol).
SERVICING REFRIGERANT OIL LEVEL
(1) Usi ng a refri gerant recovery machi ne, remove
refri gerant from the A/C system.
(2) Remove refri gerant l i nes from A/C compressor.
(3) Remove compressor from vehi cl e.
(4) From sucti on port on top of compressor, drai n
refri gerant oi l from compressor.
(5) Add system capaci ty mi nus the capaci ty of
components that have not been repl aced through suc-
ti on port on compressor. Refer to the Refri gerant Oi l
Capaci ty Chart.
(6) I nstal l compressor, connect refri gerant l i nes,
evacuate, and charge refri gerant system.
COOLDOWN TEST
GENERAL INFORMATION
I f the HVAC control modul e i s repl aced, the Cal i -
brati on Di agnosti c and Cool down tests wi l l need to
be performed. Once thi s group of tests have success-
ful l y passed, they can be performed i ndi vi dual l y. The
engi ne must be runni ng duri ng the test to provi de
hot cool ant for the heater, A/C compressor operati on
and to assure that the actuators are cal i brated cor-
rectl y. The HVAC control modul e i s capabl e of trou-
bl eshooti ng the system i n approxi matel y 120 seconds.
I f a condi ti on i s detected, an error code i s di spl ayed.
The error code cannot be erased unti l the condi ti on i s
repai red and the di agnosti c test i s performed. Check
wi re before repl aci ng components, refer to Group 8W,
Wi ri ng Di agrams.
CAUTION: Do not remove the actuators from the
Heater-A/C unit assembly with power applied.
Removal should only be done with the Ignition OFF.
The actuators have no mechanical stops to limit the
travel. If the actuator rotates and is not connected
to the unit assembly, it will become out of calibra-
tion.
ACTUATOR CALIBRATION
Mode, Bl end and Zone (i f equi pped) door cal i bra-
ti on compensates for mechani cal vari ati ons i n the
actuators, HVAC control modul e and i ts l i nkages. I n-
vehi cl e cal i brati on can be entered from the control s
front panel . I f the REAR WI PE and I NTERMI T-
TENT LEDs fl ash si mul taneousl y when I gni ti on i s
cycl ed ON, the actuators have not been cal i brated or
duri ng the previ ous cal i brati on a fai l ure occurred
(Fi g. 6) and (Fi g. 7). Di agnosti cs wi l l al ways occur
duri ng Cal i brati on Di agnosti c and Cool down test.
REFRIGERANT OIL CAPACITIES
Refrigerant
Oil Capaci-
ties
Front A/C Dual A/C
Component ml oz ml oz
Compressor 150 ml 5.0 oz 220 ml 7.4 oz
Filter-Drier 30 ml 1.0 oz 30 ml 1.0 oz
Condenser 30 ml 1.0 oz 30 ml 1.0 oz
Evaporator 60 ml 2.0 oz 60 ml 2 .0 oz
Rear Evap. N/A N/A 60 ml 2.0 oz
DIAGNOSTICS
Duri ng the Actuator cal i brati on, di agnosti cs are
performed on the actuators and evaporator tempera-
ture Fi n Sensor. Once di agnosti cs are compl eted the
REAR WI PER and I NTERMI TTENT LEDs wi l l fl ash
to i ndi cate ei ther a successful cal i brati on or the
appropri ate fai l code(s). At thi s ti me manual testi ng
of the Bl end, Mode and Dri ver (i f equi pped) potenti -
ometers can be performed. I f a fai l ure i s detected
duri ng Di agnosti cs a faul t wi l l be set i n the control .
When I gni ti on i s cycl ed OFF and then ON or Di ag-
nosti cs i s aborted, the REAR WI PER and I NTER-
MI TTENT LEDs wi l l fl ash si mul taneousl y showi ng
that a fai l ure has occurred. The control wi l l not i ndi -
cate the fai l code, but onl y that a fai l ure had
occurred duri ng the l ast di agnosti cs test. The onl y
way to cl ear the fai l ure codes i s repeat the Cal i bra-
ti on Di agnosti c and Cool down test, after al l repai rs
are compl eted.
COOLDOWN TEST
Thi s test has been desi gned for performance test-
i ng of the A/C system at the manufacturi ng faci l i ty. I f
the HVAC control modul e i s repl aced, the Cool down
test wi l l occur duri ng Cal i brati on test. Cool down wi l l
not occur on Heater Onl y uni ts. Duri ng the Cool down
test the control wi l l moni tor the temperature of the
Fi n Sensor. The A/C system must be abl e to bri ng the
evaporator temperature down a predetermi ned mi ni -
mum amount i n l ess than 2 mi nutes.
CALIBRATION/COOLDOWN LED DISPLAY
CODES
See tabl e for defi ni ti on of fl ashi ng LEDs. I f no
probl ems are found, the control functi ons normal l y.
CALIBRATION/DIAGNOSTICS TEST ENTRY
TO INITIATE TESTS:
Set Bl ower motor ON HI GH
Set Mode posi ti on to Panel
Open al l A/C outl ets
Set Temperature to Col d (Both sl i de pots i f
equi pped)
Depress WASH and REAR WI PER button si mul -
taneousl y for 5 Seconds (Unti l al l LEDs l i ght)
RESULTS:
Al l LEDs wi l l turn on for 5 Seconds
Cal i brati on Test i s runni ng when REAR WI PER
and I NTERMI TTENT are al ternatel y fl ashi ng.
Cool down test i s runni ng i f A/C and RECI RC are
al ternatel y fl ashi ng.
Acceptabl e resul ts i s REAR WI PER LED i s the
onl y LED fl ashi ng. Push Rear Wi per to exi t.
After al l tests have passed, Cal i brati on Di agnos-
ti cs and Cool down can be run separatel y.
Fig. 7 Radio Bezel and HVAC Control, Rear Blower
Motor Switch and Zone Control
CODES
LEDS PASS/FAIL
CORREC-
TIVE
ACTION
NO LEDS
FLASHING-
NORMAL
OPERATION
PASSED
CALIBRATION,
DIAGNOSTICS
AND
COOLDOWN
NONE
REAR WIPER AND
INTERMITTENT
LEDS FLASH
SIMULTANEOUSLY
FAILED
CALIBRATION
DIAGNOSTICS
RUN
CALIBRATION
TEST
A/C AND RECIRC
LEDS FLASH
SIMULTANEOUSLY
FAILED
COOLDOWN
RUN
COOLDOWN
TEST
REAR WIPER AND
INTERMITTENT
LEDS ARE
FLASHING
SIMULTANEOUSLY
A/C AND RECIRC
LEDS ARE
FLASHING
SIMULTANEOUSLY
FAILED
CALIBRATION,
DIAGNOSTICS
AND FAILED
COOLDOWN
TEST
RUN
CALIBRATION
TEST
COOLDOWN TEST ENTRY
TO INITIATE TESTS:
equi pped)
Depress WASH and A/C si mul taneousl y for 5
Seconds
NOTE: Prior to start of test, If the evaporator is
already cold, the system will fail test. To correct,
operate system with A/C OFF and the blower motor
ON high for three minutes prior to starting test.
RESULTS:
Cool down Test i s runni ng when A/C and
RECI RC. are al ternatel y fl ashi ng. I f A/C and
RECI RC. are fl ashi ng si mul taneousl y, Cool down has
fai l ed.
CALIBRATION DIAGNOSTICS AND
COOLDOWN ABORT
Test can be aborted by doi ng one of the fol l owi ng:
Depressi ng Rear Wi ndow Defogger, RECI RC and
Rear Wi per buttons.
Cycl i ng I gni ti on OFF and then ON.
Control wi l l automati cal l y abort after 15 mi n-
utes from the ti me Cal i brati on Di agnosti cs and
Cool down was entered.
The HVAC control modul e wi l l return to normal
operati on or may i ndi cate unsuccessful Cal i brati on
Di agnosti cs or Cool down test by LEDs fl ashi ng
si mul taneousl y.
EEPROM DATA
Cal i brati on Di agnosti cs, Cool down Status and
evaporator temperature Fi n Sensor val ues are stored
i n an EEPROM memory i nternal to the control . The
mi crocomputer wi thi n the HVAC control modul e uses
thi s i nformati on:
To determi ne i f Cool down needs to run
For proper posi ti on of the Heater-A/C uni t
assembl y doors
ACTUATOR CALIBRATION AND
DIAGNOSTICS.
NOTE: Do not run actuators unless they are prop-
erly mounted on the HVAC control module.
Actuator end poi nt cal i brati on takes approxi matel y
60 seconds. The REAR WI PER and I NTERMI TTENT
LEDs wi l l fl ash al ternatel y duri ng the test. The con-
trol wi l l cycl e the Bl end actuator(s) to the Heat stop
fi rst then back to Col d. After the Bl end actuator(s)
have been cal i brated the Mode actuator wi l l be cycl ed
to Defrost and then to Panel . Successful cal i brati on
i s defi ned as actuator travel fal l i ng wi thi n thei r mi n-
i mum and maxi mum l i mi ts.
BLEND/PASSENGER ACTUATOR BACKGROUND
The Bl end/Passenger Actuator can move the tem-
perature door i n two di recti ons. When the vol tage at
Pi n 12 of the control modul e i s hi gh, about 11.5 vol ts,
and the vol tage at Pi n 17 i s l ow, about 1.5 vol ts, the
door wi l l move towards the Heat posi ti on. When Pi n
17 i s Hi gh and Pi n 12 i s Low the door wi l l move
towards the Col d posi ti on. When both Pi ns are hi gh
or both Pi ns are l ow, the actuator wi l l not move. The
Bl end/Passenger feedback si gnal i s a vol tage si gnal
that i s suppl i ed by the actuator to the control . The
si gnal wi l l be about 4.0 vol ts i n the Heat posi ti on
and 1.0 vol t i n the Col d posi ti on. As the posi ti on of
the Bl end/Passenger actuator changes, so wi l l the
feedback si gnal . The feedback si gnal i s necessary for
the correct posi ti oni ng of the temperature door.
DRIVER ACTUATOR BACKGROUND
The Dri ver Actuator can move the temperature
door i n two di recti ons. When the vol tage at Pi n 15 of
the control modul e i s hi gh, about 11.5 vol ts, and the
vol tage at Pi n 13 i s l ow, about 1.5 vol ts the door wi l l
move towards the Col d posi ti on. When Pi n 13 i s Hi gh
and Pi n 15 i s Low the door wi l l move towards the
Heat posi ti on. When both Pi ns are hi gh or when both
Pi ns are l ow, the actuator wi l l not move. The Dri ver
feedback si gnal i s a vol tage si gnal that i s suppl i ed by
the actuator to the control . The si gnal wi l l be about
4.0 vol ts i n the Heat posi ti on and 1.0 vol t i n the Col d
posi ti on. As the posi ti on of the Dri ver Actuator
changes, so wi l l the feedback si gnal . The feedback
si gnal i s necessary for the correct posi ti oni ng of the
temperature door.
MODE ACTUATOR BACKGROUND
The Mode actuator can move the mode door i n two
di recti ons. When the vol tage at Pi n 18 of the control
modul e i s hi gh, about 11.5 vol ts, and the vol tage at
Pi n 12 i s l ow, about 1.5 vol ts the door wi l l move
towards the Panel posi ti on. When Pi n 12 i s Hi gh and
Pi n 18 i s Low the door wi l l move towards the Defrost
posi ti on. When both Pi n are hi gh or when both Pi ns
are l ow, the actuator wi l l not move. The Mode door
4.5 vol ts i n the Panel posi ti on and 0.5 vol ts i n the
Defrost posi ti on. As the posi ti on of the Mode actuator
mode door.
FAIL CODES/LEVEL DISPLAY
Fai l Codes/Level are di spl ayed usi ng the REAR
WI PER and I NTERMI TTENT LEDs fl ashi ng i n the
sequence i ndi cated bel ow. The REAR WI PER LED
represents the Level and the I NTERMI TTENT LED
represents the Val ue. After Cal i brati on/Di agnosti cs i s
compl eted, the control wi l l begi n fl ashi ng Level 1
codes. Depressi ng the WASH button wi l l cycl e to
Level 2, depressi ng WASH agai n wi l l cycl e to Level 3.
Each ti me the WASH button i s depressed wi l l cycl e
to the next l evel . After Level 5 i s reached, you wi l l
cycl e back to Level 1. I f the Control i s a Heater Onl y
you wi l l onl y cycl e from Level s 1 to 3.
TEMPERATURE AND MODE POTENTIOMETER
DIAGNOSTICS
The Temperature and Mode Potenti ometer can be
tested after cal i brati on i s compl ete by pressi ng the
WASH button and cycl i ng to Level s 2, 3 or 5 as di s-
pl ayed by the REAR WI PER LED. On Heater Onl y
uni ts you can onl y cycl e to Level s 2 and 3. I n each
i ndi vi dual test the I NTERMI TTENT LED fl ash rate
wi l l change as the Temperature or Mode potenti ome-
ter i s moved from one end to the other, see Potenti -
ometer vs. Posi ti on and Fl ash Rate tabl e.
EVAPORATOR PROBE TEMPERATURE
DIAGNOSTICS
The evaporator probe can be tested by usi ng the
I NTERMI TTENT LED to di spl ay the actual temper-
ature the sensor i s readi ng. The HVAC control mod-
ul e can onl y di spl ay temperatures from 1 to 99
degrees. To read the temperature, perform the fol l ow-
i ng:
Set Bl ower motor to any speed other than OFF
Set A/C to ON, i f A/C Cl utch does not engage
make sure Fai l Codes 5 and 6 are cl eared.To cl ear
the error code 5 and 6 the evaporator probe and/or
the wi ri ng repai r needs to be compl eted. Then, press
and hol d the i ntermi ttent wi pe button for 5 seconds.
Run Di agnosti cs (Depress REAR WI PER and
REAR WASH)
When Di agnosti cs i s compl ete, Cycl e to Level 4.
Di spl ay Sequence i s as fol l ows:
REAR WI PER LED wi l l di spl ay the Level
I NTERMI TTENT LED wi l l di spl ay tens di gi t
Short Pause
I NTERMI TTENT LED wi l l di spl ay the ones
di gi t.
The HVAC control modul e wi l l conti nue to cycl e
the Level and then Temperature unti l the l evel i s
changed or Cal i brati on Di agnosti cs and Cool down
test i s exi ted.
HVAC CONTROL DIAGNOSTIC CONDITIONS
For wi ri ng ci rcui ts, wi ri ng connectors, and Pi n
numbers, refer to Group 8W, Wi ri ng Di agrams.
After c alibration, Rear Wiper LED flashing
onc e, Intermittent LED not flashing.
The system has passed cal i brati on. Press the Rear
Wi per button to exi t cal i brati on.
WIPE BUTTON LED
LEVEL DISPLAY
1 FAIL CODES
2 MODE POTENTIOMETER TEST
3 BLEND/PASS. POTENTIOMETER TEST
4 EVAPORATOR PROBE (A/C AND ZONE
UNITS ONLY)
5 DRIVER POTENTIOMETER (ZONE UNITS
ONLY)
LEVEL 1FAILURE CODE VALUES
(INTERMITTENT WIPE BUTTON LED)
CODE DEFINITION
0 PASSED ALL TESTS
1 MODE ACTUATOR DID NOT REACH
DEFROST POSITION
PANEL POSITION
3 BLEND/PASS. ACTUATOR DID NOT
REACH COLD STOP
4 BLEND PASS. ACTUATOR DID NOT
REACH HEAT STOP
5 EVAPORATOR PROBE OPEN
6 EVAPORATOR PROBE SHORTED
7 DRIVER ACTUATOR DID NOT REACH
COLD STOP
8 ZONE/DRIVER ACTUATOR DID NOT
REACH HEAT STOP
9 CONTROL HEAD INTERNAL FAILURE
POTENTIOMETER VS. POSITION AND FLASH
RATE
POTENTIOM-
ETER
INTERMIT-
TENT LED
FASTER
FLASH RATE
INTERMITTENT
LED SLOWER
FLASH RATE
MODE PANEL DEFROST
BLEND/PASS. HOT COLD
DRIVER HOT COLD
onc e, Intermittent LED flashing onc e. The
mode ac tuator did not reac h defrost position.
(1) Usi ng a vol tmeter, check the mode door actua-
tor wi ri ng connector. Check Pi n 1 for battery vol tage.
Move the HVAC control from the defrost to panel
posi ti on, and check Pi n 6 vol tage i t shoul d change
from 0.5 - 1 vol ts to 3.5 - 4.5 vol ts. I f vol tage i s OK,
go to Step 2. I f not OK, check for l oose or corroded
connector, open or shorted ci rcui t and repai r as nec-
essary.
(2) Remove actuator, and check i f the gear pi ns are
i n the correct track on cam or i f they are bi ndi ng. I f
OK, go to Step 3. I f not OK, repai r as necessary.
(3) Check for bi ndi ng door, i f door i s bi ndi ng repai r
as necessary. I f gears and door are OK, repl ace
actuator.
(4) Once repai rs are compl eted repeat the Cal i bra-
ti on Di agnosti c and Cool down test. Repeati ng the
test i s necessary to cl ear the faul t codes.
onc e, Intermittent LED flashing twic e. The
mode ac tuator did not reac h panel position.
Move the HVAC control from panel to defrost posi -
ti on, and check Pi n 6 vol tage i t shoul d change from
3.5 - 4.5 vol ts to 0.5 - 1 vol ts. I f vol tage i s OK, go to
Step 2. I f not OK, check for l oose or corroded connec-
tor, open or shorted ci rcui t and repai r as necessary.
i n the correct cam track or bi ndi ng. I f OK, go to Step
3. I f not OK, repai r as necessary.
actuator.
onc e, Intermittent LED flashing three times.
The main temperature ac tuator/passenger
temperature ac tuator on a zone system did
not reac h c old stop.
(1) Check i f the correct HVAC control modul e was
used.
(2) Usi ng a vol tmeter, check the temperature door
actuator wi ri ng connector. Check Pi n 1 for battery
vol tage. Move the HVAC control from the col d to hot
essary.
(3) Remove actuator, and check i f gear pi ns are i n
the correct cam track or bi ndi ng. I f OK, go to Step 4.
I f not OK, repai r as necessary.
actuator.
onc e, Intermittent LED flashing four times.
not reac h hot stop.
used.
vol tage. Move the HVAC control from hot to col d
posi ti on and check Pi n 5 vol tage i t shoul d change
from 3.5 -4.5 vol ts 0.5 - 1.5 vol ts. I f vol tage i s OK, go
to Step 3. I f not OK, check for l oose or corroded con-
nector, open or shorted ci rcui t and repai r as neces-
sary.
actuator.
onc e, Intermittent LED flashing five times.
The evaporator probe is open.
(1) Usi ng a vol tmeter, check Pi n 1 of the evapora-
tor probe wi ri ng connector for 0.1 - 4.75 vol ts. I f OK,
go to Step 2. I f not OK, i f greater than 4.75 vol ts
check for l oose or corroded connector, open ci rcui t
(2) Usi ng a ohmmeter, check Pi n 2 for a good
ground, I f OK, go to Step 3. I f not OK, check for l oose
or corroded connector, open or shorted ci rcui t and
(3) I f ground and power ci rcui t are OK, repl ace
Evaporator Probe.
(4) Once repai rs are compl eted, press the i ntermi t-
tent button about 5 seconds unti l al l LEDs l i ght to
remove faul t code from memory. Then repeat the Cal -
i brati on Di agnosti c and Cool down test. Repeati ng the
onc e, Intermittent LED flashing six times. The
evaporator probe is shorted.
go to Step 2. I f l ess than 0.1 vol ts, check for l oose or
corroded connector, open or shorted ci rcui t and repai r
as necessary.
ground, I f OK, go to Step 3. I f not OK, check for
shorted ci rcui t and repai r as necessary.
Evaporator Probe
onc e, Intermittent LED flashing seven times.
The Drivers temperature ac tuator on a zone
system did not reac h c old stop.
used.
(2) Usi ng a vol tmeter, check at the temperature
door actuator wi ri ng connector, check Pi n 1 for bat-
tery vol tage. Move the HVAC control from col d to the
hot posi ti on, check Pi n 4 vol tage i t shoul d change
from 0.5 - 1.5 vol ts 3.5 - 4.5 vol ts. I f vol tage i s OK, go
sary.
(4) Check for bi ndi ng doors, i f door are bi ndi ng
repai r as necessary. I f gears and door are OK, repl ace
actuator.
onc e, Intermittent LED flashing eight times.
system did not reac h hot stop.
used.
tery vol tage. Move the HVAC control from hot to col d
posi ti on, Pi n 4 vol tage i t shoul d change from 3.5 - 4.5
vol ts to 0.5 - 1.5 vol ts. I f vol tage i s OK, go to Step 3.
I f not OK, check for l oose or corroded connector, open
or shorted ci rcui t and repai r as necessary.
actuator.
onc e, Intermittent LED flashing nine times.
The HVAC c ontrol module, has a internal
failure.
(1) Repl ace the HVAC control modul e.
After c alibration and testing the A/C and
RECIRC LED flashing simultaneously. Failed
Cooldown test.
(1) Determi ne i f the refri gerant system i s operat-
i ng correctl y:
Check the outl et ai r temperature
Feel the compressor sucti on pl umbi ng, i s i t hot?
(2) I f not OK, go to Step 3. I f OK, repeat the Cal -
i brati on Di agnosti c and Cool down test.
(3) I f system does not seem to be operati ng cor-
rectl y, perform di agnosti cs for poor performance:
Low refri gerant charge
No charge
Compressor not operati ng
Veri fy that the test was done wi th the evaporator
at room temperature. The test consi sts of starti ng
the compressor and measuri ng the ti me i t takes for
the evaporator temperature to fal l 7C (20F). I f the
compressor has been runni ng, the evaporator i s col d
al ready and wi l l not be capabl e of fal l i ng 7C (20F).
I f the test was run wi th a col d evaporator, turn A/C
off and turn the bl ower motor swi tch to hi gh posi ti on
for 3 to 5 mi nutes ti l l the evaporator i s to room tem-
perature. Then repeat the Cal i brati on Di agnosti c and
Cool down test.
I f refri gerant system i s performi ng properl y and
the system wi l l not pass test. Repeat the Cal i brati on
Di agnosti c and Cool down test to determi ne i f the
evaporator temperature FI N sensor has devel oped an
open or a short ci rcui t. I f the HVAC control modul e
sti l l passes Cal i brati on test, veri fy Cool down test
manual l y wi th a pocket thermometer. The outl et ai r
temperature must drop at l east 7C (20F) wi thi n
two mi nutes. I f the vehi cl e passes wi th the manual
thermometer, take HVAC control to l evel 4 (evapora-
tor probe temperature readout) and repeat the
Cool down test. Ensure the evaporator i s at room tem-
perature before starti ng test. Check i f evaporator
probe wi l l drop the temperature 7C (20F) i n two
mi nutes. I f the Evaporator Probe i s found to be
faul ty, check that the sensor i s posi ti oned i n the
evaporator fi ns properl y. I f not, correct and repeat
test. I f OK, repl ace the evaporator probe.
Once the repai rs are compl eted, repeat the Cal i bra-
A/C PERFORMANCE TEST
The ai r condi ti oni ng system i s desi gned to remove
heat and humi di ty from the ai r enteri ng the passen-
ger compartment. The evaporator, l ocated i n the
heater A/C uni t, i s cool ed to temperatures near the
freezi ng poi nt. As warm damp ai r passes over the
fi ns i n the evaporator, moi sture i n the ai r condenses
to water, dehumi di fyi ng the ai r. Condensati on on the
evaporator fi ns reduces the evaporators abi l i ty to
absorb heat. Duri ng peri ods of hi gh heat and humi d-
i ty, an ai r condi ti oni ng system wi l l be l ess effecti ve.
Wi th the i nstrument control set to RECI RC, onl y ai r
from the passenger compartment passes through the
evaporator. As the passenger compartment ai r dehu-
mi di fi es, A/C performance l evel s ri se.
PERFORMANCE TEST PROCEDURE
Revi ew Safety Precauti ons and Warni ngs i n thi s
group before proceedi ng wi th thi s procedure. Ai r tem-
perature i n test room and on vehi cl e must be 21 C
(70F) mi ni mum for thi s test.
NOTE: When connecting the service equipment
coupling to the line fitting, verify that the valve of
the coupling is fully closed. This will reduce the
amount of effort required to make the connection.
(1) Connect a tachometer and mani fol d gauge set.
(2) Set control to A/C, RECI RC, and PANEL, tem-
perature l ever on ful l cool and bl ower on hi gh.
(3) Start engi ne and hol d at 1000 rpm wi th A/C
cl utch engaged.
(4) Engi ne shoul d be warmed up wi th doors and
wi ndows cl osed.
(5) I nsert a thermometer i n the l eft center A/C
outl et and operate the engi ne for fi ve mi nutes. The
A/C cl utch may cycl e dependi ng on ambi ent condi -
ti ons.
(6) Wi th the A/C cl utch engaged, compare the di s-
charge ai r temperature to the A/C Performance Tem-
peratures tabl e.
(7) I f the di scharge ai r temperature fai l s to meet
the speci fi cati ons i n the performance temperature
chart. Refer to the Refri gerant Servi ce Procedures for
further di agnosi s.
The work area temperature must not be bel ow
10C (50F) to test the compressor cl utch ci rcui t.
Before starti ng to test the transducer ensure that the
wi re connector i s cl ean of corrosi on and connected
properl y.
(1) Wi th gear sel ector i n park or neutral and park
brake set, start engi ne and al l ow to i dl e.
(2) I nstal l scan tool (DRB):
Go to mai n menu
Sel ect stand al one scan tool (DRB)
Sel ect refer to the proper year di agnosti cs
Sel ect cl i mate control
Sel ect sensor di spl ay
Sel ect A/C hi gh si de vol ts
For A/C system to operate a vol tage between .451
(Low Pressure Cutout) to 4.519 (Hi gh Pressure Cut-
out i s requi red. Vol tages outsi de thi s range i ndi cate a
l ow or hi gh pressure condi ti on and will not al l ow
the compressor to cycl e.
Refer to the A/C Pressure Transducer Vol tage tabl e
for the appropri ate condi ti on(s):
A/C PERFORMANCE TEMPERATURES
AMBIENT TEMPERATURE 21C
(70F)
26.5C
(80F)
32C
(90F)
37C
(100F)
43C
(110F)
AIR TEMPERATURE AT LEFT
CENTER PANEL OUTLET
1-8C
(34-46F)
3-9C
(37-49F)
4-10C
(39-50F)
6-11C
(43-52F)
7-18C
(45-65F)
COMPRESSOR DISCHARGE
PRESSURE AFTER THE FILTER
DRIER
1034-1724
kPa
(150-250
PSI)
1517-2275
kPa
(220-330
PSI)
1999-2620
kPa
(290-380
PSI)
2068-2965
kPa
(300-430
PSI)
2275-3421
kPa
(330-496
PSI)
EVAPORATOR SUCTION
PRESSURE
103-207 kPa
(15-30 PSI)
117-221 kPa
(17-32 psi)
138-241 kPa
(20-35 PSI)
172-269 kPa
(25-39 PSI)
207-345 kPa
(30-50 PSI)
BLOWER MOTOR AND WHEEL ASSEMBLY
VIBRATION AND/OR NOISE DIAGNOSIS
The bl ower speed swi tch, i n conjuncti on wi th the
resi stor bl ock, suppl i es the bl ower motor wi th vari ed
vol tage.
CAUTION: Stay clear of the blower motor and resis-
tor block (Hot). Do not operate the blower motor
with the resistor block removed from the heater A/C
housing.
Refer to the Bl ower Motor Vi brati on/Noi se chart i n
thi s secti on for di agnosi s.
COMPRESSOR NOISE DIAGNOSIS
Excessi ve noi se whi l e the A/C i s bei ng used, can be
caused by l oose mounts, l oose cl utch, or hi gh operat-
i ng pressure. Veri fy compressor dri ve bel t condi ti on,
proper refri gerant charge and head pressure before
compressor repai r i s performed.
I f the A/C dri ve bel t sl i ps at i ni ti al start-up, i t does
not necessari l y mean the compressor has fai l ed.
Wi th the cl ose tol erances of a compressor i t i s pos-
si bl e to experi ence a temporary l ockup. The l onger
the A/C system i s i nacti ve, the more l i kel y the condi -
ti on to occur.
Thi s condi ti on i s the resul t of normal refri gerant
movement wi thi n the A/C system caused by temper-
ature changes. The refri gerant movement may wash
the oi l out of the compressor.
COMPRESSOR CLUTCH/COIL
The ai r condi ti oni ng compressor cl utch el ectri cal
ci rcui t i s control l ed by the Powertrai n Control Mod-
ul e. I t i s l ocated i n the engi ne compartment outboard
of the battery.
I f the compressor cl utch does not engage veri fy
refri gerant charge.
I f the compressor cl utch sti l l does not engage check
for battery vol tage at the pressure transducer l ocated
on the l i qui d l i ne. I f vol tage i s not detected, refer to:
Group 8W, Wi ri ng di agrams.
Powertrai n Di agnosti c Procedures manual for
di agnosti c i nformati on.
I f vol tage i s detected at the pressure transducer,
connect pressure transducer and check for battery
vol tage between the compressor cl utch connector ter-
mi nal s.
I f vol tage i s detected, perform A/C Cl utch Coi l
Tests.
TESTS
(1) Veri fy battery state of charge. (Test i ndi cator i n
battery shoul d be green).
(2) Connect an ampmeter (0-10 ampere scal e) i n
seri es wi th the cl utch coi l termi nal . Use a vol tmeter
(0-20 vol t scal e) wi th cl i p l eads measuri ng vol tage
across the battery and A/C cl utch.
(3) Wi th A/C control i n A/C mode and bl ower at
l ow speed, start the engi ne and run at normal i dl e.
(4) The A/C cl utch shoul d engage i mmedi atel y and
the cl utch vol tage shoul d be wi thi n two vol ts of the
battery vol tage. I f the A/C cl utch does not engage,
test the fuse.
(5) The A/C cl utch coi l i s acceptabl e i f the current
draw i s 2.0 to 3.7 amperes at 11.5-12.5 vol ts at cl utch
coi l . Thi s i s wi th the work area temperature at 21C
(70F). I f vol tage i s more than 12.5 vol ts, add el ectri -
cal l oads by turni ng on el ectri cal accessori es unti l
vol tage reads bel ow 12.5 vol ts.
(6) I f coi l current reads zero, the coi l i s open and
shoul d be repl aced. I f the ammeter readi ng i s 4
amperes or more, the coi l i s shorted and shoul d be
repl aced. I f the coi l vol tage i s not wi thi n two vol ts of
the battery vol tage, test cl utch coi l feed ci rcui t for
excessi ve vol tage drop.
EXPANSION VALVE
TESTS
NOTE: Expansion valve tests should be performed
after compressor tests.
group. The work area and vehi cl e temperature must
A/C PRESSURE TRANSDUCER VOLTAGE
VOLTAGE CONDITION
0 TRANSDUCER FAULTY
OR NO VOLTAGE FROM
PCM
.150 TO .450 TRANSDUCER
GOOD/LOW PRESSURE
CUTOUT CONDITION
.451 TO 4.519 NORMAL OPERATING
CONDITION
4.520 TO 4.850 TRANSDUCER
GOOD/HIGH
PRESSURE CUTOUT
CONDITION
5 TRANSDUCER FAULTY
Blower Motor Noise/Vibration Diagnosis
be 21C to 27C (70F to 85F). To test the expansi on
val ve:
NOTE: Liquid CO2 is required to test the expansion
valve. It is available from most welding supply facil-
ities. CO2 is also available from companies which
service and sell fire extinguishers.
(1) Connect a chargi ng stati on or mani fol d gauge
set to the refri gerant system servi ce ports. Veri fy the
refri gerant charge l evel .
(2) Cl ose al l doors, wi ndows and vents to the pas-
senger compartment.
(3) Set heater A/C control to A/C, ful l heat,
FLOOR, and hi gh bl ower.
(4) Start the engi ne and al l ow to i dl e (1000 rpm).
After the engi ne has reached runni ng temperature,
al l ow the passenger compartment to heat up. Thi s
wi l l create the need for maxi mum refri gerant fl ow
i nto the evaporator.
(5) I f the refri gerant charge i s suffi ci ent, di scharge
(hi gh pressure) gauge shoul d read 965 to 1655 kPa
(140 to 240 psi ). Sucti on (l ow pressure) gauge shoul d
read 140 kPa to 207 kPa (20 psi to 30 psi g). I f system
cannot achi eve proper pressure readi ngs, repl ace the
expansi on val ve. I f pressure i s correct, proceed wi th
test.
WARNING: PROTECT SKIN AND EYES FROM CON-
TACTING CO2 PERSONAL INJURY CAN RESULT.
(6) I f sucti on si de l ow pressure i s wi thi n speci fi ed
range, freeze the expansi on val ve control head for 30
seconds. Use a super col d substance (l i qui d CO2). Do
not spray R-134a or R-12 Refrigerant on the
expansion valve for this test. Sucti on si de l ow
pressure shoul d drop by 10 psi . I f not, repl ace expan-
si on val ve.
(7) Al l ow expansi on val ve to thaw. The l ow pres-
sure gauge readi ng shoul d stabi l i ze at 140 kPa to
240 kPa (20 psi to 30 psi g). I f not, repl ace expansi on
val ve.
(8) When expansi on val ve test i s compl ete, test
A/C overal l performance. Remove al l test equi pment
HEATER PERFORMANCE TEST
PRE-DIAGNOSTIC PREPARATIONS
group before performi ng the fol l owi ng procedures.
Check the cool ant l evel , dri ve bel t tensi on, vacuum
l i ne connecti ons, radi ator ai r fl ow and fan operati on.
Start engi ne and al l ow to warm up to normal tem-
perature.
WARNING: DO NOT REMOVE RADIATOR CAP
WHEN ENGINE IS HOT, PERSONAL INJURY CAN
RESULT.
I f vehi cl e has been run recentl y, wai t 15 mi nutes
before removi ng cap. Pl ace a rag over the cap and
turn i t to the fi rst safety stop. Al l ow pressure to
escape through the overfl ow tube. When the system
stabi l i zes, remove the cap compl etel y.
MAXIMUM HEATER OUTPUT: TEST AND
ACTION
Engi ne cool ant i s provi ded to the heater system by
two 16 mm (5/8 i nch i nsi de di ameter) heater hoses.
Wi th engi ne i dl i ng at normal runni ng temperature,
set the control to maxi mum heat, fl oor, and hi gh
bl ower setti ng. Usi ng a test thermometer, check the
ai r temperature comi ng from the fl oor outl ets, refer
to Temperature Reference Tabl e.
I f the fl oor outl et ai r temperature i s i nsuffi ci ent,
refer to Group 7, Cool i ng Systems for speci fi cati ons.
Both heater hoses shoul d be HOT to the touch (cool -
ant return hose shoul d be sl i ghtl y cool er than the
suppl y hose). I f cool ant return hose i s much cool er
than the suppl y hose, l ocate and repai r engi ne cool -
ant fl ow obstructi on i n heater system.
POSSIBLE LOCATIONS OR CAUSE OF
OBSTRUCTED COOLANT FLOW
(1) Pi nched or ki nked heater hoses.
(2) I mproper heater hose routi ng.
(3) Pl ugged heater hoses or suppl y and return
ports at cool i ng system connecti ons, refer to Group 7,
Cool i ng System.
(4) Pl ugged heater core.
(5) Ai r l ocked heater core.
(6) I f cool ant fl ow i s veri fi ed and outl et tempera-
ture i s i nsuffi ci ent, a mechani cal probl em may exi st.
POSSIBLE LOCATION OR CAUSE OF
INSUFFICIENT HEAT
(1) Obstructed cowl ai r i ntake.
(2) Obstructed heater system outl ets.
(3) Bl end-ai r door not functi oni ng properl y.
TEMPERATURE REFERENCE TABLE
AMBIENT
TEMPERATURE
MINIMUM FLOOR
OUTLET TEMPERATURE
CELSIUS FAHRENHEIT CELSIUS FAHRENHEIT
15.5 60 62.2 144
21.1 70 63.8 147
26.6 80 65.5 150
32.2 90 67.2 153
TEMPERATURE CONTROL
I f temperature cannot be adjusted wi th the TEMP
l ever on the control panel , the fol l owi ng coul d requi re
servi ce:
(1) Bl end-ai r door bi ndi ng.
(2) Faul ty bl end-ai r door motor.
(3) I mproper engi ne cool ant temperature.
(4) Faul ty I nstrument Panel Control .
SYSTEM CHARGE LEVEL TEST
The procedure bel ow shoul d be used to check
and/or fi l l the refri gerant charge i n the ai r condi ti on-
i ng system.
NOTE: The amount of R134a refrigerant that the air
conditioning system holds is:
Wi thout rear A/C .96 kg (34 oz. or 2.13 l bs.)
Wi th Rear A/C 1.36 kg (48 oz. or 3.00 l bs.)
NOTE: Low Charge, condition may be described
as:
Loss of A/C performance
Fog from A/C outlets
evaporator may have a HISS sound
There are two di fferent ways the system can be
tested:
Wi th a scan tool (DRB), thermocoupl e and the
Charge Determi nati on Graph. Use the scan tool
(DRB) di agnosti c topi c: Engi neSystem Moni tors, A/C
Pressure.
Usi ng a mani fol d gauge set, a thermocoupl e and
the Charge Determi nati on Graph.
I t i s recommended to use the gauges or recl ai m/re-
cycl e equi pment.
WARNING: AVOID BREATHING A/C REFRIGERANT
AND LUBRICANT VAPOR OR MIST. EXPOSURE MAY
IRRITATE EYES, NOSE AND THROAT. USE ONLY
APPROVED SERVICE EQUIPMENT MEETING SAE
REQUIREMENTS TO DISCHARGE R-134a SYSTEM.
IF ACCIDENTAL SYSTEM DISCHARGE OCCURS,
VENTILATE WORK AREA BEFORE RESUMING SER-
VICE.
R-134a SERVICE EQUIPMENT OR VEHICLE A/C
SYSTEM SHOULD NOT BE PRESSURE TESTED OR
LEAK TESTED WITH COMPRESSED AIR. SOME
MIXTURES OF AIR/R-134a HAVE BEEN SHOWN TO
BE COMBUSTIBLE AT ELEVATED PRESSURES.
THESE MIXTURES ARE POTENTIALLY DANGER-
OUS AND MAY RESULT IN FIRE OR EXPLOSION
CAUSING INJURY OR PROPERTY DAMAGE.
(1) Establ i sh your preferred method of measuri ng
l i qui d l i ne pressure. Use a mani fol d gauge set or a
DRB scan tool .
(2) Attach a cl amp-on thermocoupl e (P.S.E. 66-324-
0014 or 80PK-1A) or equi val ent to the l i qui d l i ne. I t
must be pl aced as cl ose to the A/C Pressure Trans-
ducer as possi bl e to observe l i qui d l i ne temperature.
Refer to Thermocoupl e Probe i n thi s secti on for
more i nformati on on probe.
(3) The vehi cl e must be i n the fol l owi ng modes:
Transaxl e i n Park
Engi ne I dl i ng at 700 rpm
A/C Control s Set to Outsi de Ai r
Panel Mode
Ful l Cool
Hi gh Bl ower motor, (vehi cl e equi pped wi th rear
A/C turn rear bl ower motor ON HI GH)
A/C Button i n the ON posi ti on
Vehi cl e Wi ndows Open.
Reci rc. button turned OFF
(4) Operate system for a coupl e of mi nutes to al l ow
the system to stabi l i ze.
(5) Set system pressure to about 1793 kPa (260
psi ) by pl aci ng a pi ece of cardboard over part of the
front si de of the condenser. To pl ace cardboard prop-
erl y, remove the upper radi ator-condenser cover.
I nsert cardboard between condenser and radi ator
front. Thi s wi l l mai ntai n a constant pressure.
(6) Observe Li qui d Li ne pressure and Li qui d l i ne
temperature. Usi ng the Charge Determination
Chart determi ne where the system i s currentl y oper-
ati ng. I f the system i s i n the undercharged regi on,
ADD 0.057 Kg. (2 oz.) to the system and recheck
readi ngs. I f the system i s i n the overcharged regi on,
RECLAI M 0.057 Kg. (2 oz.) from the system and
recheck readi ngs. Conti nue thi s process unti l the sys-
tem readi ngs are i n the proper charge area on the
Charge Determination Chart.
(7) The same procedure can be performed usi ng
the scan tool (DRB). To determi ne l i qui d l i ne pres-
sure, attach the scan tool , go to System Moni -
torsA/C Pressure. Observe l i qui d l i ne pressure from
A/C Pressure Transducer on di gi tal di spl ay and di gi -
tal thermometer. Refer to Charge Determination
Chart and determi ne where the system i s operati ng.
SERVICE PROCEDURES
R-134a REFRIGERANT
Thi s vehi cl e uses a new type of refri gerant cal l ed
R-134a. I t i s a non-toxi c, non-fl ammabl e, cl ear col or-
l ess l i quefi ed gas.
R-134a refri gerant i s not compati bl e wi th R-12
refri gerant i n an ai r condi ti oni ng system. Even a
smal l amount of R-12 i n a R-134a system coul d cause
compressor fai l ure, refri gerant oi l to sl udge and/or
poor performance. Never add any other type of
refrigerant to a system designed to use R-134a
refrigerant. System failure will occur.
The hi gh pressure servi ce port i s l ocated on the l i q-
ui d l i ne near the strut tower. The l ow pressure ser-
vi ce port i s l ocated on the sucti on l i ne near the
compressor mani fol d.
When servi ci ng a system, i t i s requi red that an ai r
condi ti oni ng chargi ng recovery/recycl i ng machi ne be
used (Fi g. 8). Contact an automoti ve servi ce equi p-
ment suppl i er for proper equi pment. Refer to the
operati ng i nstructi ons provi ded wi th the equi pment
for proper operati on.
A mani fol d gauge set (Fi g. 9) must al so be used i n
conjuncti on wi th the chargi ng and/or recovery/recy-
cl i ng devi ce. Onl y use gauges that have not been
used for R-12. The servi ce hoses on the gauge set
shoul d have manual (turn wheel ) or automati c back
fl ow val ves at the servi ce port connector ends. Thi s
wi l l prevent refri gerant R-134a from bei ng rel eased
i nto the atmosphere.
R-134a refri gerant requi res a speci al type of com-
pressor oi l . When addi ng oi l , make sure to use the oi l
that i s speci fi ed on the under hood l abel .
Due to the di fferent characteri sti cs of R-134a i t
requi res al l new servi ce procedures.
The use of R-134a wi l l have a posi ti ve envi ronmen-
tal i mpact due to i ts zero ozone depl eti on and l ow
gl obal warmi ng i mpact.
CHARGING REFRIGERANT SYSTEM
CAUTION: Do not overcharge refrigerant system,
as excessive compressor head pressure can cause
noise and system failure.
After the system has been tested for l eaks and
evacuated, a refri gerant (R-134a) charge can be
i njected i nto the system.
Charge Determination Chart
Fig. 8 Refrigerant Recovery/Recycling Station
(Typical)
(1) Connect mani fol d gauge set.
(2) Measure refri gerant (refer to capaci ti es) and
heat to 52C (125F) wi th the chargi ng stati on. Refer
to the i nstructi ons provi ded wi th the equi pment
bei ng used.
REFRIGERANT CAPACITIES
Wi thout Rear A/C = .96 kg (34 oz. or 2.13l b.)
Wi th Rear A/C = 1.36 kg (48 oz. or 3.00 l b.)
(3) Open the sucti on and di scharge val ves. Open
the charge val ve to al l ow the heated refri gerant to
fl ow i nto the system. When the transfer of refri ger-
ant has stopped, cl ose the sucti on and di scharge
val ve.
(4) I f al l of the charge di d not transfer from the
di spensi ng devi ce, run engi ne at a hi gh i dl e (1400
rpm). Set the A/C control to A/C, l ow bl ower speed,
and open wi ndows. I f the A/C compressor does not
engage, test the compressor cl utch control ci rcui t and
correct any fai l ure. Refer to Group 8W, Wi ri ng Di a-
grams.
(5) Open the sucti on val ve to al l ow the remai ni ng
refri gerant to transfer to the system.
WARNING: TAKE CARE NOT TO OPEN THE DIS-
CHARGE (HIGH-PRESSURE) VALVE AT THIS TIME.
(6) Cl ose al l val ves and test the A/C system perfor-
mance.
(7) Di sconnect the chargi ng stati on or mani fol d
gauge set. I nstal l the servi ce port caps.
EVACUATING REFRIGERANT SYSTEM
NOTE: Special effort must be used to prevent mois-
ture from entering the A/C system oil. Moisture in
the oil is very difficult to remove and will cause a
I f a compressor desi gned to use R-134a refri gerant
i s l eft open to the atmosphere for an extended peri od
of ti me. I t i s recommended that the refri gerant oi l be
drai ned and repl aced wi th new oi l or a new compres-
sor be used. Thi s wi l l el i mi nate the possi bi l i ty of con-
tami nati ng the refri gerant system.
I f the refri gerant system has been open to the
atmosphere, i t must be evacuated before the system
can be fi l l ed. Moi sture and ai r mi xed wi th the refri g-
erant wi l l rai se the compressor head pressure above
acceptabl e operati ng l evel s. Thi s wi l l reduce the per-
formance of the ai r condi ti oner and damage the com-
pressor. Moi sture wi l l boi l at near room temperature
when exposed to vacuum. To evacuate the refri gerant
system:
(1) Connect a sui tabl e chargi ng stati on, refri gerant
recovery machi ne, and a mani fol d gauge set wi th
vacuum pump (Fi g. 10).
(2) Open the sucti on and di scharge val ves and
start the vacuum pump. The vacuum pump shoul d
run a mi ni mum of 45 mi nutes pri or to charge to
Fig. 9 Manifold Gauge Set- Typical
Fig. 10 Refrigerant Recovery Machine Hookup
el i mi nate al l moi sture i n system. When the sucti on
gauge reads -88 kPa (- 26 i n. Hg) vacuum or greater
for 45 mi nutes, cl ose al l val ves and turn off vacuum
pump. I f the system fai l s to reach speci fi ed vacuum,
the refri gerant system l i kel y has a l eak that must be
corrected. I f the refri gerant system mai ntai ns speci -
fi ed vacuum for at l east 30 mi nutes, start the vac-
uum pump, open the sucti on and di scharge val ves.
Then al l ow the system to evacuate an addi ti onal 10
mi nutes.
(3) Cl ose al l val ves. Turn off and di sconnect the
vacuum pump.
(4) The refri gerant system i s prepared to be
charged wi th refri gerant.
THERMOCOUPLE PROBE
To di agnose the A/C system, a temperature probe i s
requi red to measure l i qui d l i ne temperature. The
cl amp-on type K probe shown i n thi s manual i s avai l -
abl e through the Chrysl er Professi onal Servi ce
Equi pment (PSE) program. Thi s probe i s compati bl e
wi th temperature-measuri ng i nstruments that accept
Type K Thermocoupl es and have a mi ni ature connec-
tor i nput. Other temperature probes are avai l abl e
through aftermarket sources. Al l references i n thi s
manual wi l l refl ect the use of the probe made avai l -
abl e through the Professi onal Servi ce Equi pment pro-
gram.
I n order to use the temperature probe, a di gi tal
thermometer wi l l be requi red. I f a di gi tal thermome-
ter i s not avai l abl e, an adapter i s avai l abl e through
the Professi onal Servi ce Equi pment program. I t can
convert any standard di gi tal mul ti meter i nto a ther-
mometer. Thi s adapter i s desi gned to accept any
standard K-type thermocoupl e.
I f a di gi tal mul ti meter i s not avai l abl e, i t to can be
ordered through Professi onal Servi ce Equi pment pro-
gram.
BUTTONS
To servi ce HVAC control modul e push buttons that
are sti cki ng, spray between the buttons wi th Mopar
MP-50. The MP-50 i s a al l purpose l ubri cant for
mechani cal and el ectri cal uses. After sprayi ng around
the push buttons wi pe any excess off the radi o bezel
and HVAC control modul e push buttons. Operate the
buttons to ensure that they are operati ng freel y.
SYSTEM LEAK CHECKING
WARNING: R-134a SERVICE EQUIPMENT OR VEHI-
CLE A/C SYSTEM SHOULD NOT BE PRESSURE
TESTED OR LEAK TESTED WITH COMPRESSED
AIR. SOME MIXTURES OF AIR/R-134a HAVE BEEN
DAMAGE.
I f the A/C system i s not cool i ng properl y, determi ne
i f the refri gerant system i s ful l y charged wi th
R-134a. Thi s i s accompl i shed by performi ng a system
Charge Level -Check or Fi l l . I f whi l e performi ng thi s
test A/C l i qui d l i ne pressure i s l ess than 207 kPa (30
psi ) proceed to Empty Refri gerant System Leak Test.
I f l i qui d l i ne pressure i s greater than 207 kPa (30
psi ) proceed to l ow refri gerant l evel l eak test. I f the
refri gerant system i s empty or l ow i n refri gerant
charge, a l eak at any l i ne fi tti ng or component seal i s
l i kel y. A revi ew of the fi tti ngs, l i nes and components
for oi l y resi due i s an i ndi cati on of the l eak l ocati on.
To detect a l eak i n the refri gerant system, perform
one of the fol l owi ng procedures as i ndi cated by the
symptoms.
VICE.
EMPTY REFRIGERANT SYSTEM LEAK TEST
(1) Evacuate the refri gerant system to the l owest
degree of vacuum possi bl e (about 28 i n Hg.). Deter-
mi ne i f the system hol ds a vacuum for 15 mi nutes. I f
vacuum i s hel d, a l eak i s probabl y not present. I f sys-
tem wi l l not mai ntai n vacuum l evel , proceed wi th
thi s procedure.
(2) Prepare a .284 Kg. (10 oz.) refri gerant charge
to be i njected i nto the system.
(3) Connect and di spense .284 Kg. (10 oz.) of
refri gerant i nto the evacuated refri gerant system.
(4) Proceed to step two of Low Refri gerant Level
Leak Test.
LOW REFRIGERANT LEVEL LEAK TEST
(1) Determi ne i f there i s any (R-134a) refri gerant
i n the system. Use the scan tool (DRB) under the
menu Systems SensorsA/C Pressure test or pressure
gauge l i qui d l i ne temperature parti al charge check.
See system charge l evel check or fi l l for procedure.
(2) Posi ti on the vehi cl e i n a wi nd free work area.
Thi s wi l l ai d i n detecti ng smal l l eaks.
(3) Bri ng the refri gerant system up to operati ng
temperature and pressure. Thi s i s done by al l owi ng
the engi ne to run for fi ve mi nutes wi th the system
set to the fol l owi ng:
Transaxl e i n Park
A/C Control s Set i n 100 percent outsi de ai r
Ful l Panel Mode
Bl ower motor ON HI GH
A/C i n the ON posi ti on
Front Wi ndows Open.
Rear Ai r Off (I f Equi pped)
CAUTION: A leak detector designed for R-12 refrig-
erant will not detect leaks in a R-134a refrigerant
system.
(4) Shut off the vehi cl e and wai t 2 to 7 mi nutes.
Then use an El ectroni c Leak Detector that i s
desi gned to detect R-134a type refri gerant and search
for l eaks. Fi tti ngs, l i nes, or components that appear
to be oi l y usual l y i ndi cates a refri gerant l eak. To
i nspect the evaporator core for l eaks, i nsert the l eak
detector probe i nto the reci rcul ati ng ai r door openi ng
or a heat duct.
I f a thorough l eak check has been compl eted wi th-
out i ndi cati on of a l eak, proceed to System Charge
Level -Check or Fi l l .
REMOVAL
(1) Di sconnect the wi re connector at the pressure
transducer.
(2) Usi ng an open end wrench, remove the trans-
ducer from the l i qui d l i ne (Fi g. 11).
INSTALLATION
(1) Repl ace transducer O-ri ng.
A/C SERVICE PORTS
WARNING: THE REFRIGERATION SYSTEM MUST
BE COMPLETELY EMPTY BEFORE PROCEEDING
WITH THIS OPERATION.
The Hi gh Si de servi ce port i s servi ceabl e, the Low
Si de i s not servi ceabl e.
REMOVAL
(2) Recover A/C system refri gerant.
(3) Unscrew the Hi gh Si de servi ce port from the
l i qui d l i ne.
(4) Remove O-ri ng
INSTALLATION
Install new O-ring.
Evacuate and recharge A/C system.
BLEND-AIR DOOR ACTUATOR
REMOVAL
The ai r condi ti oni ng system can be equi pped wi th
ei ther a standard, si ngl e bl end-ai r door actuator, or i t
can be equi pped wi th dual actuators. The dual sys-
tem has separate bl end-ai r control s. Thi s al l ows for
separate control of the dri vers si de ai r, and the pas-
senger si de ai r (Fi g. 12).
(1) Remove the l ower l eft si de steeri ng col umn
cover. Refer to Group 8E, I nstrument Panel and Sys-
tems.
(2) Remove ABS control modul e (Fi g. 13).
(3) Remove bl end-ai r actuator connector.
(4) Remove bl end-ai r actuator (Fi g. 14).
INSTALLATION
Fig. 11 A/C Pressure Transducer Removal
Fig. 12 Side View Of HVAC With Actuators
(2) Perform the HVAC Control Cal i brati on Di ag-
nosti c and Cool down test. Repeati ng the test i s nec-
essary to cl ear the faul t codes.
REMOVAL
(1) Remove gl ove box. Refer to Group 8E, I nstru-
ment Panel and Systems.
(2) Remove (4) hex head screws to bl ower motor
cover (Fi g. 15).
(3) Di sconnect bl ower motor wi ri ng.
(4) Remove grommet for wi ri ng (Fi g. 16). Feed wi r-
i ng through bl ower housi ng (Fi g. 17).
(5) Remove mounti ng screws for bl ower motor (Fi g.
18).
(6) Al l ow the bl ower assembl y to drop down, and
remove assembl y from vehi cl e.
INSTALLATION
BLOWER MOTOR RESISTOR BLOCK
REMOVAL
(1) Open hood.
(2) Di sconnect and i sol ate negati ve battery cabl e.
Fig. 13 ABS Control Module
Fig. 14 Blend-Air Actuator
Fig. 15 Blower Motor Cover
Fig. 16 Wiring Grommet
Fig. 17 Feeding Wiring Through Housing
(3) Locate and remove the wi re connector from the
bl ower resi stor bl ock. Bl ock i s l ocated at the back of
the engi ne compartment on the passenger si de of the
vehi cl e under the wi per modul e (Fi g. 19).
NOTE: It may not necessary to remove the wiper
module to access the resistor block.
(4) Usi ng a l ong fl ad bl ade screwdri ver, gentl y
push i n on dri vers si de of resi stor. Be careful to catch
the i nner rel ease tang and gentl y pry outward (Fi g.
20).
WARNING: THE RESISTOR BLOCK MAY BE HOT.
DO NOT ATTEMPT TO SERVICE THE RESISTOR
BLOCK IF THE SYSTEM HAS BEEN RUNNING
RECENTLY. LET THE SYSTEM COOL DOWN
BEFORE REPAIRS ARE INITIATED.
(5) Remove resi stor bl ock by i nserti ng a fl at bl ade
pry tool on the si de of the resi stor bl ock and pushi ng
i nward. Two gui de l i nes are shown on the ri ght hand
edge of the resi stor bl ock to hel p gui de the bl ade
posi ti on. Thi s wi l l rel ease the cl i ps on the si de of the
resi stor bl ock. Pul l resi stor bl ock out.
INSTALLATION
Make sure the TOP l etteri ng i s on the top of the
resi stor. The coi l s on the Resi stor Bl ock shoul d not be
contacti ng one another. Before i nstal l ati on, gentl y
separate the coi l s (wi th fi ngers onl y) i f one coi l i s
contacti ng another.
BLOWER MOTOR WHEEL
The bl ower motor wheel i s not servi ced separatel y.
I f the wheel needs to be repl aced i t i s servi ced as an
assembl y of the bl ower motor. For servi ce procedure
i nformati on, refer to Bl ower Motor Repl acement i n
thi s group.
Fig. 18 Blower Motor Screws
Fig. 19 Resistor Block Location
Fig. 20 Resistor Block Removal
COMPRESSOR
REMOVAL
WARNING: REFER TO REFRIGERANT SERVICE
PROCEDURES FOR INFORMATION REGARDING
PROPER RECOVERY OF THE REFRIGERANT
BEFORE ATTEMPTING TO REMOVE THE COM-
PRESSOR.
(2) Pi nch off cool ant l i nes to rear Heat uni t (i f
equi pped). Drai n engi ne cool ant.
(3) Remove upper radi ator hose.
(4) Remove dri ve bel t (refer to Group 7, Cool i ng
System). Di sconnect compressor cl utch wi re l ead.
(5) Remove refri gerant l i nes from compressor (Fi g.
21) and (Fi g. 22).
(6) Remove compressor nuts and bol ts (Fi g. 23).
(7) Remove compressor (Fi g. 24).
INSTALLATION
REMOVAL
(1) Remove the compressor shaft bol t (Fi g. 25). A
band type oi l fi l ter removal tool can be pl aced around
the cl utch pl ate to ai d i n bol t removal .
Fig. 21 Suction Line
Fig. 22 Discharge line
Fig. 23 Compressor Mounts
Fig. 24 Compressor Removal
CAUTION: Do not use screwdrivers between the
clutch plate assembly and pulley to remove front
plate as this may damage the front plate assembly.
(2) Tap the cl utch pl ate wi th a pl asti c hammer and
remove cl utch pl ate and shi m (Fi g. 26).
(3) Remove pul l ey retai ni ng snap ri ng wi th snap
ri ng pl i ers (C-4574), and sl i de pul l ey assembl y off of
compressor (Fi g. 27).
(4) Remove coi l wi re cl i p screw and wi re harness.
(5) Remove snap ri ng retai ni ng fi el d coi l onto com-
pressor housi ng (Fi g. 28). Sl i de fi el d coi l off of com-
pressor housi ng.
(6) Exami ne fri cti onal faces of the cl utch pul l ey
and front pl ate for wear. The pul l ey and front pl ate
shoul d be repl aced i f there i s excessi ve wear or scor-
i ng. I f the fri cti on surfaces are oi l y, i nspect the shaft
nose area of the compressor for oi l and remove the
fel t from the front cover. I f the compressor fel t i s sat-
urated wi th oi l , the shaft seal i s l eaki ng and wi l l
have to be repl aced.
(7) Check beari ng for roughness, excessi ve l eakage
or grease. I f grease from beari ng has contami nated
the faces of the pul l ey or front pl ate, they shoul d be
repl aced. I f the beari ng i s rough or bi nds, repl ace
cl utch pul l ey and front pl ate assembl y.
Fig. 25 Compressor Shaft Bolt and Clutch Plate
Fig. 26 Clutch Plate and Shim(s)
Fig. 27 Removing Pulley Snap Ring
Fig. 28 Clutch Coil Snap Ring
CAUTION: The clutch pulley and the front plate
were mated at the factory by a burnishing opera-
tion. No attempt should be made to separately
replace either part. This will result in clutch slip-
page due to insufficient contact area.
INSTALLATION
(1) Al i gn pi n i n back of fi el d coi l wi th hol e i n com-
pressor end housi ng, and posi ti on fi el d coi l i nto pl ace.
Make sure that l ead wi res are properl y routed, and
fasten wi th the wi re cl i p screw.
(2) I nstal l fi el d coi l retai ni ng snap ri ng wi th snap
ri ng pl i ers. The bevel si de of the snap ri ng faci ng
outward. Al so both snap ri ng eyel ets must be to the
ri ght or l eft of the pi n on compressor. Press snap ri ng
to make sure i t i s properl y seated i n the groove.
CAUTION: If snap ring is not fully seated it will
vibrate out, resulting in a clutch failure and severe
damage to the front face of the compressor.
(3) I nstal l pul l ey assembl y to compressor. I f neces-
sary, tap gentl y wi th a bl ock of wood on the fri cti on
surface (Fi g. 29).
CAUTION: Do not mar the pulley frictional surface.
(4) I nstal l pul l ey assembl y retai ni ng snap ri ng
(bevel si de outward) wi th snap ri ng pl i ers. Press the
snap ri ng to make sure i t i s properl y seated i n the
groove.
(5) I f the ori gi nal front pl ate assembl y and pul l ey
assembl y are to be reused, the ol d shi m(s) can be
used. I f not, pl ace a tri al stack of shi ms, 1 mm (0.040
i n.) thi ck, on the shaft agai nst the shoul der.
(6) I nstal l front pl ate assembl y onto shaft.
(7) Wi th the front pl ate assembl y ti ght agai nst the
shi m(s), measure the ai r gap between front pl ate and
pul l ey face wi th feel er gauges. The ai r gap shoul d be
between 0.5 and 0.9 mm (.020 and .035 i nch) I f
proper ai r gap i s not obtai ned, add or subtract shi ms
unti l desi red ai r gap i s obtai ned.
(8) I nstal l compressor shaft bol t. Ti ghten to
17.52 Nm (15520 i n. l bs.).
NOTE: Shims may compress after tightening shaft
nut. Check air gap in four or more places to verify if
air gap is still correct. Spin pulley for final check.
CLUTCH BREAK-IN
After a new cl utch has been i nstal l ed, check the
vol tage and amperage to the cl utch (determi ne i t to
be sati sfactory). Then cycl e the A/C cl utch approxi -
matel y 20 ti mes (5 sec. on and 5 sec. off). For thi s
procedure, set the system to the A/C mode, usi ng
hi gh bl ower, and engi ne rpm at 1500-2000. Thi s pro-
cedure (burni shi ng) wi l l seat the opposi ng fri cti on
surfaces and provi de a hi gher cl utch torque capabi l -
i ty.
CONDENSER ASSEMBLY
REMOVAL
(2) Remove l i qui d l i ne at fi l ter-dri er (Fi g. 30).
(3) Remove (2) bol ts attachi ng fi l ter-dri er to radi a-
tor modul e (Fi g. 31).
(5) Ti l t radi ator rearward.
(6) Remove upper di scharge l i ne at condenser (Fi g.
32).
(7) Through fasci a, remove l ower l i qui d l i ne from
fi l ter-dri er.
(8) Remove (2) l ower condenser mounti ng bol ts.
(9) Remove (2) upper mounti ng bol ts.
(10) Remove condenser from vehi cl e (Fi g. 33).
Fig. 29 Installing Pulley Assembly
INSTALLATION
NOTE: Inspect Cooling Module for presence of
seals. Verify seals are available for re-installation.
(1) Before i nstal l ati on, repl ace al l O-ri ngs and gas-
kets, coat al l seal i ng surfaces wi th approved wax-free
refri gerant oi l . Then, reverse the above procedures.
(2) Torque the fol l owi ng components to speci fi ca-
ti ons:
Li qui d l i ne at fi l ter/dri er 45 i n. l bs. 10.
Upper di scharge l i ne at condenser 180 i n. l bs.
20
Lower l i qui d l i ne to condenser 180 i n. l bs.
20.
(2) l ower, condenser mounti ng bol ts 45 i n. l bs.
10.
(2) upper, condenser mounti ng bol ts 45 i n. l bs.
10.
(3) Evacuate and charge system.
DISCHARGE LINE
REMOVAL
(2) Remove di scharge l i ne mounti ng nut at com-
pressor (Fi g. 34).
(3) Remove di scharge l i ne at the top fi tti ng on the
condenser (Fi g. 35).
Fig. 30 Liquid Line
Fig. 31 Filter-Drier
Fig. 32 Upper Discharge Line
Fig. 33 Condenser Removal
INSTALLATION
Repl ace al l O-ri ngs. Torque di scharge l i ne at con-
denser bol t to 180 i n. l bs. 10.
(2) Evacuate and recharge A/C system.
nosti c and Cool down test.
EVAPORATOR PROBE
REMOVAL
(1) Remove the gl ove box. Refer to Group 8E,
I nstrument Panel and Systems.
(2) Di sconnect the evaporator probe connector (Fi g.
36).
(3) Usi ng a fl at bl ade pry tool , pry the evaporator
probe grommet from the HVAC housi ng (Fi g. 37).
(4) Remove evaporator probe from evaporator (Fi g.
38).
INSTALLATION
For i nstal l ati on, reverse the above procedures. Three
hol es are provi ded i n evaporator for probe l ocati on.
When rei nstal l i ng probe, use a di fferent hol e than ori g-
i nal one. I f a new evaporator i s i nstal l ed, i nsert the
probe i n the uppermost hol e provi ded.
Fig. 34 Compressor Discharge Line
Fig. 35 Condenser Discharge Line
Fig. 36 Evaporator Probe Connector
Fig. 37 Evaporator Probe Grommet
Fig. 38 Evaporator Probe
EXPANSION VALVE
REMOVAL
(3) Remove the accessory dri ve bel t.
(4) Remove upper generator bracket.
(5) Di sconnect generator fi el d wi re connector.
(6) Push generator forward.
(7) Remove ground wi re at dash panel .
(8) Remove the nut retai ni ng the refri gerant l i ne
seal i ng pl ate to the expansi on val ve (Fi g. 39).
(9) Remove the stud from the expansi on val ve (Fi g.
40).
(10) Careful l y pul l the refri gerant l i ne seal i ng
pl ate assembl y from expansi on val ve towards the
front of the vehi cl e. Use care not to scratch the
expansi on val ve seal i ng surfaces wi th pi l ot tubes.
(11) Cover the openi ngs to prevent contami nati on.
(12) Remove two screws securi ng the expansi on
val ve to the evaporator seal i ng pl ate (Fi g. 40).
(13) Careful l y remove expansi on val ve (Fi g. 41).
(14) Remove the ol d O-ri ngs.
INSTALLATION
(1) Ensure ol d O-ri ngs are removed. I nstal l new
O-ri ngs on the refri gerant l i nes and evaporator seal -
i ng pl ate.
(2) Hand-start the stud i nto the expansi on val ve
and torque to 7 - 11 Nm (64 - 96 i n. l bs.).
(3) Careful l y i nstal l the expansi on val ve to the
seal i ng pl ate. I nstal l the two screws and ti ghten 8 to
14 Nm (70 to 130 i n. l bs.) torque.
(4) Careful l y i nstal l the refri gerant l i nes and seal -
i ng pl ate to the expansi on val ve. I nstal l the nut and
ti ghten 20 to 26 Nm (170 to 230 i n. l bs.) torque.
(5) I nstal l the ground wi re at dash panel .
(6) Pul l generator back i nto the proper posi ti on for
bracket mounti ng.
(7) I nstal l generator fi el d wi re connector.
(8) I nstal l the upper generator bracket.
(9) I nstal l accessory dri ve bel t.
(10) Evacuate and recharge system.
(11) After expansi on val ve i s i nstal l ed, the system
i s charged, and l eaks have checked repeat the A/C
performance check.
FILTER-DRIER ASSEMBLY
REMOVAL
Fig. 39 A/C Refrigerant Line Plate
Fig. 40 Expansion Valve Stud and Mounting Screws
Fig. 41 Expansion Valve Removal
(3) Remove the (2) bol ts hol di ng fi l ter-dri er bracket
to radi ator fan modul e bracket.
(4) Remove the l ower l i qui d l i ne at condenser.
(5) Remove the upper radi ator crossmember.
(6) Pul l up on radi ator and sl i de fi l ter-dri er from
the mounti ng l ocati on.
INSTALLATION
(1) Before i nstal l ati on, repl ace both refri gerant
l i ne O-ri ngs. Then reverse the above procedures.
Torque fi l ter/dri er mounti ng bol ts to 45 i n. l bs. 10.
HEATER A/C UNIT HOUSING
REMOVAL
WARNING: IF EQUIPPED WITH AIR CONDITIONING,
THE REFRIGERATION SYSTEM MUST BE COM-
PLETELY EMPTY BEFORE PROCEEDING.
(1) Set parki ng brake.
refri gerant from the A/C system (Fi g. 43).
Wi ndshi el d Wi pers and Washers.
(5) Pi nch off rear heater l i nes i f equi pped.
(6) Drai n engi ne cool ant. Remove heater hoses at
the heater core (Fi g. 44). Pl ug cool ant l i nes.
(7) Remove sucti on and l i qui d l i nes at the expan-
si on val ve (Fi g. 45).
(8) Remove the I nstrument Panel Assembl y. Refer
to Group 8E, I nstrument Panel and Gauges.
(9) Remove heater ducts.
Fig. 42 Filter-Drier Assembly
Fig. 43 A/C Service Ports
Fig. 44 Heater Hoses
Fig. 45 Expansion Valve Plate
(10) Di sconnect the two upper mounts from the
upper rei nforcement and the l ower mount from the
tunnel .
(11) Remove the (3) nuts (i n the engi ne compart-
ment) securi ng the uni t to the dash panel (Fi g. 46).
(12) Di sconnect the HVAC housi ng wi ri ng harness.
(13) Pul l the enti re uni t rearward unti l the studs
on the uni t cl ear the dash panel . Drop the uni t down.
Pul l i t rearward to remove i t from vehi cl e.
INSTALLATION
(1) For i nstal l ati on of the assembl y, reverse the
above procedures. I nstal l new O-ri ngs on pl umbi ng
i nl ets
(2) Evacuate and recharge the A/C system.
(3) Perform HVAC control Cal i brati on Di agnosti c
and Cool down test.
HEATER CORE
REMOVAL
(1) Drai n cool ant system.
(2) Remove l eft si de l ower col umn cover.
(3) Remove steeri ng col umn assembl y. Refer to
Group 19, Steeri ng for servi ce procedure.
(4) Remove ABS modul e, bracket and wi ri ng (Fi g.
47).
(5) Remove I /P to body harness i nterconnect and
bracket (Fi g. 48).
(6) Remove l ower si l encer boot at base of steeri ng
shaft (Fi g. 49)
(7) Pi nch off heater l i nes under the hood.
(8) Remove heater core cover. I nsert a smal l
amount of towel s under the heater core tubes.
Remove heater core pl ate and tubes (Fi g. 50).
(9) Depress heater core retai ni ng cl i ps (Fi g. 51).
(10) Pul l up on accel erator pedal and sl i de heater
core past (Fi g. 52).
(11) Depress brake pedal (Fi g. 53) and remove
heater core from HVAC housi ng.
Fig. 46 HVAC Bolt-Up
Fig. 47 ABS MODULE
Fig. 48 Interconnect And Bracket
Fig. 49 Lower Silencer Boot
INSTALLATION
I nstal l screws to retai n heater core i n housi ng.
Repl ace heater core tube i nl et O-ri ngs. Ti ghten
heater core tube retai ni ng pl ate to 3 1 Nm (27
HEATER HOSES
REMOVAL
NOTE: Review Safety Precautions and Warnings
before proceeding with this operation.
(1) Drai n engi ne cool i ng system. Refer to Group 7,
Engi ne Cool i ng.
(2) Loosen cl amps at each end of heater hose to be
removed (Fi g. 54) and (Fi g. 55).
Fig. 50 Heater Core Plate And Tubes
Fig. 51 Depress Clips
Fig. 52 Accelerator Pedal
Fig. 53 Brake Pedal
Fig. 54 Upper Heater Hose
CAUTION: When removing hoses from heater core
inlet or outlet nipples, do not use excessive force.
Heater core may become damaged and leak engine
coolant.
(3) Careful l y rotate hose back and forth whi l e tug-
gi ng sl i ghtl y away from connector ni ppl e. I f the hose
wi l l not come off, sl i ce the hose at the connector ni p-
pl e and peel off heater hose. Thi s method wi l l requi re
heater hose repl acement.
INSTALLATION
LIQUID LINE
REMOVAL
40).
(8) Remove l i qui d l i ne from expansi on val ve.
(10) Di sconnect wi re connector at pressure trans-
ducer.
(11) Remove l i qui d l i ne mounti ng bracket at ri ght
frame rai l .
(12) Usi ng access sl ot between radi ator crossmem-
ber and gri l l e, l oosen l i qui d l i ne mounti ng pl ate at
fi l ter-dri er. Remove l i qui d l i ne from fi l ter-dri er. I t
may be necessary to bend l i qui d l i ne i n hal f to
remove l i ne. The repl acement l i ne i s a two-pi ece
assembl y.
INSTALLATION
I nstal l the stud to the evaporator seal i ng pl ate
and ti ghten 7 to 11 Nm (64 to 96 i n. l bs.) torque.
Install new O-rings.
I nstal l two-pi ece l i ne i n pl ace of ori gi nal part.
Assembl e l i ne hal ves after i t i s i nstal l ed on vehi cl e.
MODE DOOR ACTUATOR
REMOVAL
tems.
(3) Remove mode actuator connector (Fi g. 57).
(4) Remove mode door actuator (Fi g. 58).
INSTALLATION
Fig. 55 Lower Heater Hose
Fig. 57 Mode Door Actuator Connector
(2) Perform the HVAC control Cal i brati on Di agnos-
ti c and Cool down test.
SIDE WINDOW DEMISTER DUCTS
LEFT SIDE
The LEFT si de wi ndow demi ster duct i s a two
pi ece desi gn. The l eft si de has a l ong duct that
attaches to an i ntermedi ate duct and then to the di s-
tri buti on housi ng. The duct i s l ocated on top of the
i nstrument panel . To servi ce the duct, remove the I /P
cover and remove duct retai ners/fasteners. (Fi g. 59).
RIGHT SIDE
The demi ster duct on the ri ght si de i s a one pi ece
desi gn. I t i s one l ong duct that attaches to the di stri -
buti on housi ng. The duct i s l ocated on top of the
i nstrument panel and i t i s not servi ceabl e (Fi g. 60).
SUCTION LINE
REMOVAL
40).
(8) Remove sucti on l i ne from expansi on val ve.
(9) Remove sucti on l i ne mounti ng nut at compres-
sor (Fi g. 61).
(10) Remove sucti on l i ne mounti ng bracket.
(11) Remove sucti on l i ne.
INSTALLATION
Fig. 58 Mode Door Actuator
Fig. 59 Left Side Demister Duct
Fig. 60 Right Side Demister Duct
Fig. 61 Suction Line At Compressor
Assembl e l i ne hal ves after i t i s i nstal l ed on vehi -
cl e.
RECIRC DOOR ACTUATOR
REMOVAL
(1) Pul l back on carpeti ng on the ri ght l ower fl oor.
(2) Remove Reci rc. door actuator connector.
(3) Remove (3) mounti ng screws for Reci rc. actua-
tor (Fi g. 62).
(4) Remove Reci rc. actuator.
(5) Di sengage actuator l i nkage at Reci rc. door.
(6) Remove actuator from vehi cl e.
INSTALLATION
HEATER A/C UNIT RECONDITION
Heater A/C Housi ng must be removed from vehi cl e
before performi ng thi s operati on. Refer to Heater A/C
Uni t Housi ngRemoval and I nstal l ati on.
DISASSEMBLYEVAPORATOR HOUSING
(1) Pl ace HVAC uni t assembl y on workbench.
(2) Remove di stri buti on housi ng mounti ng screws
(Fi g. 63).
(3) Remove bl ower motor cover (Fi g. 64).
(4) Remove bl ower motor wi ri ng grommet and feed
wi ri ng through bl ower housi ng (Fi g. 65).
(5) Remove bl ower motor screws. Remove bl ower
motor from housi ng (Fi g. 66) and (Fi g. 67).
(6) Remove reci rcul ati on door cover (Fi g. 68).
(7) Remove Reci rc. door (Fi g. 69).
(8) Remove screws around the peri meter of the
upper HVAC housi ng (Fi g. 70).
Fig. 62 Recirculation Door Actuator
Fig. 63 Distribution Housing
Fig. 65 Blower Motor Grommet
CAUTION: Do not damage the insulation barrier
surrounding the evaporator.
(9) Careful l y pul l up on evaporator and remove
from housi ng (Fi g. 71).
(10) I f repl aci ng evaporator, drai n and measure
amount of oi l from ol d evaporator and add new oi l of
the same amount (ND8 PAG) to the new evaporator
before i nstal l i ng. Use SP 10 PAG oi l for 2.5L di esel
and 2.0L gasol i ne engi ne vehi cl es.
ASSEMBLYEVAPORATOR HOUSING
(1) For reassembl y of the evaporator housi ng,
reverse the above procedures.
DISASSEMBLYDISTRIBUTION HOUSING
(1) Pl ace di stri buti on housi ng on workbench (Fi g.
72).
(2) Remove heater core cover (Fi g. 73).
(3) Remove heater core tube pl ate (Fi g. 74) and
(Fi g. 75).
(4) Remove heater core tubes (Fi g. 76).
Fig. 67 Blower Motor
Fig. 68 Recirculation Door Cover
Fig. 69 Recirc. Door
Fig. 70 HVAC Cover
(5) Depress heater core retai ni ng cl i ps at housi ng.
When rei nstal l i ng core use screws to fasten the
heater core to the housi ng.
(6) Sl i de heater core out of the housi ng.
(7) Remove dri vers zone actuator from di stri buti on
(8) Remove passenger zone actuator from di stri bu-
ti on housi ng (Fi g. 78).
Fig. 71 Evaporator
Fig. 73 Heater Core Cover
Fig. 74 Heater Core Tube Plate
Fig. 75 Plate Removal
Fig. 76 Heater Core Tube Removal
(9) Usi ng a l ong thi n fl at bl ade tool , i nsert tool
through bl end-ai r openi ng on top of di stri buti on
housi ng (Fi g. 79). Depress cl i p retai ni ng the dri vers
bl end-ai r door dri ve gear. Pul l out on gear and
remove from the housi ng (Fi g. 80).
(10) Remove mode door motor.
(11) Remove Panel door actuator gear (Fi g. 81).
(12) Remove defrost door actuator gear (Fi g. 82).
Fig. 77 Drivers Zone Actuator
Fig. 78 Passenger Zone Actuator
Fig. 80 Blend-Air Door Drive Gear
Fig. 81 Panel Door Gear
Fig. 82 Defrost Door Gear
(13) Remove cam wheel (Fi g. 83).
(14) Remove heat door actuator gear (Fi g. 84).
(15) Remove di stri buti on housi ng l ower cover
screws (Fi g. 85).
(16) Remove di stri buti on housi ng hal f screws (Fi g.
86).
(17) Remove di stri buti on housi ng front cover (Fi g.
87) and (Fi g. 88).
(18) Remove weather-stri p at fresh-ai r vent.
(19) Separate housi ng hal ves (Fi g. 89).
(20) Pul l up on separator pl ate and remove defrost
door (Fi g. 90).
Fig. 83 Cam Wheel
Fig. 84 Heat Door Gear
Fig. 86 Distribution Housing Half Screws
Fig. 87 Front Cover
(21) Remove upper hal f Panel door (Fi g. 91).
(22) Remove upper hal f of Fl oor door (Fi g. 92).
(23) Remove upper hal f of the bl end-ai r door (sl i de
off of shaft) (Fi g. 93).
(24) Remove separator pl ate from di stri buti on
(25) Remove l ower hal f of the bl end-ai r door (Fi g.
95).
(26) Remove l ower hal f of the Panel door (Fi g. 96).
Fig. 88 View of Zone Control Doors
Fig. 89 Distribution Housing Halves
Fig. 90 Defrost Door
Fig. 91 Panel Door
Fig. 92 Floor Door
Fig. 93 Blend-Air Door
(27) Remove l ower hal f of the Fl oor door (Fi g. 97).
ASSEMBLYDISTRIBUTION HOUSING
For reassembl y of the di stri buti on housi ng, reverse
the above procedures.
To reassembl e the di stri buti on housi ng actuator
gears an assembl y procedure of the gears and cam i s
necessary.
ACTUATOR GEARS ALIGNMENT PROCEDURE
(1) I nstal l l ower FLOOR door actuator gear to
housi ng. Match master spl i ne of FLOOR door actua-
tor gear to master spl i ne on door.
(2) I nstal l cam wheel . Al i gn cam wheel track to
FLOOR door actuator gear.
(3) Al i gn cam wheel sl ot wi th the post on the di s-
tri buti on housi ng marked 1.
(4) I nstal l PANEL door actuator gear. Al i gn master
spl i ne of PANEL door actuator gear to master spl i ne
on PANEL door. Posi ti on actuator gear wi thi n cam
wheel track.
(5) I nstal l DEFROST door actuator gear to hous-
i ng. Match master spl i ne of DEFROST door actuator
to master spl i ne on DEFROST door. Posi ti on actuator
gear wi thi n cam wheel track.
(6) Rei nstal l housi ng i n vehi cl e.
Fig. 97 Lower Floor Door
Fig. 94 Separator Plate
Fig. 95 Lower Blend-Air Door
Fig. 96 Lower Panel Door
REAR HEATING AND AIR CONDITIONING SYSTEM
INDEX
page page
GENERAL INFORMATION
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . 41
REAR BLOWER RESISTOR BLOCK . . . . . . . . . . 41
REAR HEATER AND A/C LINES . . . . . . . . . . . . . 41
SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . 41
DIAGNOSTIC PROCEDURES . . . . . . . . . . . . . . . 43
AIR DISTRIBUTION DUCT-A/C . . . . . . . . . . . . . . 43
AIR DISTRIBUTION DUCT-HEATER . . . . . . . . . . 43
EVAPORATOR AND EXPANSION VALVE . . . . . . 44
MODE DOOR ACTUATOR . . . . . . . . . . . . . . . . . 49
MODE DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
REAR AIR CONDITIONING LINES . . . . . . . . . . . 45
REAR HEATER A/C AIR OUTLETS . . . . . . . . . . . 45
REAR HEATER A/C BLOWER MOTOR . . . . . . . . 46
REAR HEATER A/C UNIT . . . . . . . . . . . . . . . . . . 46
REAR HEATER CORE . . . . . . . . . . . . . . . . . . . . 48
REAR HEATER LINES . . . . . . . . . . . . . . . . . . . . 49
REAR HEATER-A/C AUXILIARY CONDENSER . . 45
REAR HEATER-A/C CONTROL ILLUMINATION
BULB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
GENERAL INFORMATION
INTRODUCTION
For proper operati on of the rear heati ng A/C sys-
tem, refer to Owners Manual suppl i ed wi th the vehi -
cl e.
REAR BLOWER RESISTOR BLOCK
The rear bl ower motor resi stor i s not servi ceabl e
separatel y. The resi stor i s i ntegral to the bl ower
motor. I f resi stor i s faul ty, i t i s necessary to repl ace
the compl ete bl ower motor.
REAR HEATER AND A/C LINES
The rear heater and A/C l i nes are al l servi ced as
i ndi vi dual pi eces. When di sconnecti ng any l i ne or
bl ock ensure that the area around i t i s cl ean of any
contami nati ons that can get i n to the system (Fi g. 1),
(Fi g. 2), (Fi g. 4), (Fi g. 3) and (Fi g. 5).
SYSTEM OPERATION
The auxi l i ary rear heati ng-ai r/condi ti oni ng uni t i s
l ocated i n the ri ght rear quarter panel . The rear
heater A/C control operates i n conjuncti on wi th the
front heater A/C control . A four posi ti on two speed
bl ower (overri de) swi tch i s l ocated on the front
Heater A/C control panel (Fi g. 6). The operator can
use the rear heater A/C bl ower swi tch to operate the
bl ower, regardl ess of the rear control setti ng. I n the
OFF posi ti on, the rear control wi l l not functi on. I n
the ON (RR) posi ti on, the rear control wi l l functi on
normal l y provi di ng three speeds (Fi g. 7). The mode
setti ng i s control l ed by the front A/C control panel .
Fig. 1 Rear Heater and A/C Lines
Ai r from i nsi de the vehi cl e i s drawn i nto the ai r
i ntake gri l l e i n the ri ght rear quarter tri m panel . The
ai r enters the bl ower and i s pushed through the
heater core and A/C evaporator coi l . The ai r di rec-
ti on, fl oor or overhead, i s determi ned by the posi ti on
of the dri vers temperature control l ever on the front
HVAC system control . I f the temperature control
l ever i s bel ow 20% heat, the auxi l i ary HVAC system
ai rfl ow wi l l come from the overhead ai r outl ets. I n
between 20% and 80%, the ai rfl ow wi l l remai n i n the
l ast posi ti on sel ected. I n other words, i f the dri ver
started out i n ful l heat and then adjusted thei r tem-
perature l ever to 30% heat as they became comfort-
abl e, the rear ai r woul d come out the fl oor outl ets the
whol e ti me.
Fig. 2 Front Lines Connected to Rear Lines
Fig. 3 Rear Heater Hose Connection
Fig. 4 Rear heater hose quick connects
Fig. 5 Rear A/C Block Connection
Fig. 6 A/C Control Panel
When di agnosi ng el ectri cal probl ems i n the auxi l -
i ary rear heater or rear A/C system, refer to Group
When di agnosi ng probl ems i n the auxi l i ary sys-
tems, refer to di agnosti c secti ons for front heater A/C.
AIR DISTRIBUTION DUCT-A/C
REMOVAL
(1) Remove quarter tri m panel , D-pi l l ar, and head-
l i ner (Fi g. 8). Refer to Group 23, Body.
(2) Remove screws securi ng D-pi l l ar duct to quar-
ter panel . Pul l duct up and away from uni t.
(3) Remove screws securi ng duct to rear header
(Fi g. 9).
(4) Remove screws securi ng duct to ri ght and l eft
rai l s (Fi g. 10).
INSTALLATION
AIR DISTRIBUTION DUCT-HEATER
REMOVAL
(1) Remove quarter tri m panel and D-pi l l ar (Fi g.
8) and (Fi g. 11). Refer to Group 23, Body.
(2) Remove screws securi ng l ower heat duct to
housi ng.
INSTALLATION
Fig. 7 Rear Blower Switch
Fig. 8 Quarter Trim Panel
Fig. 9 Rear Crossover Duct
Fig. 10 Upper A/C Duct
EVAPORATOR AND EXPANSION VALVE
REMOVAL
WARNING: THE REFRIGERANT SYSTEM MUST BE
EMPTY BEFORE PERFORMING THE FOLLOWING
OPERATION. THE ENGINE COOLING SYSTEM
MUST ALSO BE RELIEVED OF ALL PRESSURE.
(1) Remove ri ght quarter tri m panel and D-pi l l ar
tri m. Refer to Group 23, Body.
(2) Remove fan A/C di stri buti on duct.
(3) Remove rear A/C uni t.
(4) Remove bl ower scrol l .
(5) Remove evaporator cover (Fi g. 12).
(6) Remove the nut that mounts the refri gerant
pl umbi ng bl ock to the expansi on val ve (Fi g. 13).
(7) Careful l y pul l the evaporator and expansi on
val ve strai ght out of uni t (Fi g. 14). Do not scratch
the seal i ng surfaces wi th the pl umbi ng extensi on
tube pi l ots.
(8) Remove and di scard the O-ri ngs between the
pl umbi ng extensi on and the expansi on val ve.
(9) Cover the pl umbi ng extensi on seal i ng surface
to prevent contami nati on.
(10) Bri ng evaporator and expansi on val ve to a
cl ean work space.
(11) Remove two 1/4-20 Torx Head screws.
(12) Remove expansi on val ve.
(13) Measure and record the amount of resi dual oi l
from the removed evaporator.
INSTALLATION
(1) Repl ace the O-ri ngs.
(2) Hol d expansi on val ve agai nst evaporator seal -
i ng pl ate (do not scratch the seal i ng surface). I nstal l
two screws and ti ghten to 11 3 Nm (100 30 i nch
pounds) torque.
Fig. 11 Rear Heat-A/C Unit
Fig. 12 Evaporator Cover
Fig. 13 Expansion Valve
Fig. 14 Evaporator Removal
CAUTION: Do not damage the evaporator insulation
liner during installation.
(3) Careful l y i nstal l the evaporator and expansi on
val ve strai ght i nto the uni t. Do not scratch the seal -
i ng surfaces wi th the pl umbi ng extensi on tube pi l ots.
(4) Determi ne the amount of ol d refri gerant oi l
drai ned from the evaporator. Add thi s amount (of
cl ean refri gerant oi l ) back i nto the system.
(5) Careful l y al i gn the expansi on val ve onto the
pi l ot tubes of the pl umbi ng extensi on (do not scratch
the seal i ng surface). I nstal l the bol t through the
pl umbi ng pl ate i nto the uni t seal i ng pl ate. Ti ghten
bol ts to 23 3 Nm (200 30 i nch pounds) torque.
(6) I nstal l evaporator cover and bl ower scrol l .
(7) I nstal l quarter tri m panel , evacuate/charge sys-
tem, and perform the performance test.
REAR AIR CONDITIONING LINES
REMOVAL
(1) Hoi st vehi cl e
(2) Remove compressi on fi tti ngs to the sucti on and
l i qui d l i nes l ocated on the ri ght, outboard si de of the
underbody, rearward of the front crossmember. (Fi g.
2)
(3) remove (1) bol t securi ng a/c l i nes to bl ock
l ocated on the ri ght, outboard si de of the underbody,
rearward of the rear wheel and ti re. (Fi g. 5)
(4) Remove (3) straps securi ng underbody l i nes.
(Fi g. 1)
(5) Separate and remove a/c l i nes from vehi cl e.
INSTALLATION
kets. Coat al l seal i ng surfaces wi th approved wax-
free refri gerant oi l . Then, reverse the above
procedures.
REAR HEATER A/C AIR OUTLETS
REMOVAL
Separate barrel from bezel by pul l i ng outward.
INSTALLATION
For i nstal l ati on, push the outl et fi rml y i nto the
openi ng unti l i t l ocks i nto pl ace.
REAR HEATER-A/C AUXILIARY CONDENSER
I f vehi cl e i s equi pped wi th a 3.3L or 3.8L engi ne
wi th rear heater and ai r condi ti oni ng, i t wi l l be
equi pped wi th an auxi l i ary condenser. The auxi l i ary
condenser i s mounted on the pri mary condenser i n
front of the radi ator. Both condenser must be
removed as an assembl y and then separated.
The condenser assembl y must fi rst be removed
from vehi cl e. Refer to CONDENSER ASSEMBLY
removal and i nstal l ati on i n thi s secti on for servi ce
procedures.
REMOVAL
(1) After condenser assembl y removal , pl ace on
bench for di sassembl y.
(2) Remove (1) bol t to l i qui d l i ne on auxi l i ary con-
denser.
(3) Remove (4) attachi ng bol ts and separate auxi l -
i ary from pri mary condenser. (Fi g. 15)
INSTALLATION
kets. Coat al l seal i ng surfaces wi th approved wax-
free refri gerant oi l . Then, reverse the above
procedures.
Fig. 15 3.3L/3.8L REAR HEAT-A/C AUXILIARY
CONDENSER
REAR HEATER A/C BLOWER MOTOR
REMOVAL
(1) Remove the ri ght quarter tri m panel and D-pi l -
l ar tri m. Refer to Group 23, Body for servi ce proce-
dures.
(2) Remove (5) screws securi ng the bl ower motor
housi ng to the rear of the HVAC housi ng (one screw
l ocated on evaporator cover) (Fi g. 16).
(3) Twi st motor out of scrol l housi ng.
(4) Di sconnect bl ower motor wi ri ng connector.
INSTALLATION
REAR HEATER-A/C CONTROL ILLUMINATION BULB
REMOVAL
(1) Remove rear heater-A/C control from tri m
panel .
(2) On the back of control opposi te from the wi re
connectors, l ocate the bul b socket l ug.
(3) Rotate the socket countercl ockwi se and pul l the
socket from the control .
INSTALLATION
Refer to Group 8L, Lamps for bul b usage.
REAR HEATER A/C UNIT
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH REAR
A/C, THE REFRIGERANT SYSTEM MUST BE EMP-
TIED BEFORE PERFORMING THE FOLLOWING
OPERATION. THE ENGINE COOLING SYSTEM
MUST ALSO BE RELIEVED OF ALL PRESSURE.
refri gerant from the A/C system. Di sconnect A/C
pl umbi ng from rear heater A/C uni t.
(3) Remove A/C l i nes at l ower fl oor pan fl ange
(Fi g. 17).
(4) Remove (3) A/C uni t fl oor mounti ng nuts (Fi g.
18).
(6) Remove ri ght quarter tri m panel and D-pi l l ar
tri m (Fi g. 8). Refer to Group 23, Body.
(7) Remove screws securi ng ai r di stri buti on duct to
the rear wheel housi ng (Fi g. 19).
Fig. 17 A/C Lines
Fig. 18 A/C Mounting
(8) Pi nch off heater l i nes at heater core hookup
(Fi g. 20).
(9) Remove heater hoses at heater core (Fi g. 21).
(10) Remove quarter tri m panel mounti ng bracket
(Fi g. 22).
(11) Remove bl ower motor wi ri ng harness connec-
tor.
(12) Remove rear upper duct tri m screw (Fi g. 23).
(13) Remove (2) Heater-A/C housi ng mounti ng
bol ts (Fi g. 24).
(14) Pul l up on upper A/C duct. Ti l t A/C uni t out-
ward (Fi g. 25).
(15) Li ft the uni t enough to cl ear fl oor pan.
Remove uni t from the vehi cl e.
INSTALLATION
I nstal l new O-ri ngs at refri gerant l i nes. Evacuate
and charge the refri gerant system. Fi l l the heater
core (Fi g. 26). Test for l eaks and overal l performance.
Fig. 19 Lower Heater Duct
Fig. 20 Heater Core Lines
Fig. 21 Heater Hoses
Fig. 22 Trim Panel Mounting Bracket
Fig. 23 Upper Duct Trim
NOTE: If the heater core was emptied and was not
prefilled, it is necessary to thermal cycle the vehicle
TWICE. The heater core is positioned higher than
the radiator fill cap. Therefore the heater core will
not gravity fill to level. To thermal cycle the vehicle,
it must be operated till the thermostat opens, then
turned off and allowed to cool. In order to verify
that the auxiliary unit is filled completely, the follow-
ing procedure can be used:
Vehi cl e at room temperature.
Engi ne i s brought up to operati ng temperature.
Front uni t i s OFF, temperature sl i des are at ful l
HEAT posi ti on.
Engi ne i s at i dl e.
Wi th rear bl ower motor ON HI GH.
Di scharge ai r temperature, measured at the
dual regi ster l ocated on the C-pi l l ar base, i s between
135 and 145 F.
REAR HEATER CORE
REMOVAL
(1) Remove the l ower ri ght quarter tri m panel .
Refer to Group 23, Body.
(2) I sol ate and di sconnect l i nes from heater core
(Fi g. 27).
(3) Remove heater core retai ni ng screws.
(4) Careful l y pul l the heater core and tubes up and
strai ght out of the uni t.
INSTALLATION
For i nstal l ati on, reverse the above procedures. Pre-
fi l l the heater core (Fi g. 26). Test for l eaks and over-
al l performance.
Fig. 24 Mounting Bolts
Fig. 25 A/C Unit Replacement
Fig. 26 Filling Heater Core
Fig. 27 Heater Core Lines
NOTE: If the heater core was emptied and was not
prefilled, it is necessary to thermal cycle the vehicle
TWICE. The heater core is positioned higher than
the radiator fill cap. Therefore the heater core will
not gravity fill to level. To thermal cycle the vehicle,
it must be operated till the thermostat opens, then
turned off and allowed to cool. In order to verify
that the auxiliary unit is filled completely, the follow-
ing procedure can be used:
Vehi cl e at room temperature.
Engi ne i s brought up to operati ng temperature.
Front uni t i s OFF, temperature sl i des are at ful l
HEAT posi ti on.
Engi ne i s at i dl e.
Wi th rear bl ower motor ON HI GH
Di scharge ai r temperature, measured at the
dual regi ster l ocated on the C-pi l l ar base, i s between
57C to 62C (135 and 145 F).
REAR HEATER LINES
REMOVAL
(1) Parti al l y drai n engi ne cool i ng system. Refer to
Group 7, Engi ne Cool i ng.
(2) Loosen cl amp at the front end of the hose
l ocated at the ri ght, outboard si de of the underbody,
rearward of the front crossmember. (Fi g. 2)
CAUTION: When removing hoses from outlet nip-
ples, do not use excessive force. Outlet nipples
may become damaged and leak engine coolant.
(4) Compress i nsert i n rear heater hose qui ck con-
necti on and pul l downward on hose. (Fi g. 4)
(5) Remove (3) straps securi ng underbody l i nes.
(Fi g. 1)
(6) Separate and remove rear heater l i nes from
vehi cl e.
INSTALLATION
MODE DOOR
REMOVAL
(1) Remove A/C uni t.
(2) Pl ace uni t on bench.
(3) Remove heater core.
(4) Remove bl ower scrol l .
(5) Remove evaporator cover.
(6) Remove A/C l i ne to expansi on val ve mounti ng
nut.
(7) Careful l y pul l evaporator out of housi ng.
(8) Remove mode door actuator and gear exten-
si on.
(9) Remove Heater-A/C housi ng cl i ps and screws.
(10) Separate housi ng hal ves.
(11) Remove mode door.
INSTALLATION
MODE DOOR ACTUATOR
REMOVAL
(1) Remove A/C uni t.
(2) Pl ace uni t on bench.
(3) Remove mode door actuator connector.
(4) Remove mode door actuator mounti ng screws
and remove actuator.
INSTALLATION
HEATING AND AIR CONDITIONING
CONTENTS
page page
GENERAL INFORMATION
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . 1
SAFETY PRECAUTIONS AND WARNINGS . . . . 2
A/C PRESSURE TRANSDUCER . . . . . . . . . . . . 2
A/C SERVICE PORTS . . . . . . . . . . . . . . . . . . . . 2
AIR DISTRIBUTION DUCTS . . . . . . . . . . . . . . . 2
COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . 2
COMPRESSOR HIGH-PRESSURE RELIEF
VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
CONDENSATE DRAIN . . . . . . . . . . . . . . . . . . . . 3
ENGINE COOLING SYSTEM REQUIREMENTS . 3
EVAPORATOR PROBE . . . . . . . . . . . . . . . . . . . 3
HANDLING TUBING AND FITTINGS . . . . . . . . 3
HVAC CONTROL MODULE . . . . . . . . . . . . . . . . 3
SIDE DOOR HEATER A/C OUTLETS . . . . . . . . 4
SIDE WINDOW DEMISTER . . . . . . . . . . . . . . . 4
SYSTEM AIRFLOW . . . . . . . . . . . . . . . . . . . . . 4
SYSTEM OIL LEVEL . . . . . . . . . . . . . . . . . . . . . 4
A/C PERFORMANCE TEST . . . . . . . . . . . . . . . 11
A/C PRESSURE TRANSDUCER . . . . . . . . . . . 11
COOLDOWN TEST . . . . . . . . . . . . . . . . . . . . . 5
BLOWER MOTOR AND WHEEL ASSEMBLY . 12
COMPRESSOR CLUTCH/COIL . . . . . . . . . . . . 12
COMPRESSOR NOISE DIAGNOSIS . . . . . . . . 12
EXPANSION VALVE . . . . . . . . . . . . . . . . . . . . 14
HEATER PERFORMANCE TEST . . . . . . . . . . . 14
HVAC CONTROL DIAGNOSTIC CONDITIONS . 9
SYSTEM CHARGE LEVEL TEST . . . . . . . . . . . 15
SERVICE PROCEDURES
CHARGING REFRIGERANT SYSTEM . . . . . . . 17
EVACUATING REFRIGERANT SYSTEM . . . . . 17
R-134a REFRIGERANT . . . . . . . . . . . . . . . . . . 16
BUTTONS . . . . . . . . . . . . . . . . . . . . . . . . . . 18
SYSTEM LEAK CHECKING . . . . . . . . . . . . . . . 19
THERMOCOUPLE PROBE . . . . . . . . . . . . . . . 18
A/C PRESSURE TRANSDUCER . . . . . . . . . . . 19
A/C SERVICE PORTS . . . . . . . . . . . . . . . . . . . 19
BLEND-AIR DOOR ACTUATOR . . . . . . . . . . . 20
BLOWER MOTOR AND WHEEL ASSEMBLY . 20
BLOWER MOTOR RESISTOR BLOCK . . . . . . 21
BLOWER MOTOR WHEEL . . . . . . . . . . . . . . . 22
COMPRESSOR (2.5L TURBO DIESEL) . . . . . 22
CONDENSER ASSEMBLY . . . . . . . . . . . . . . . . 23
DISCHARGE LINE . . . . . . . . . . . . . . . . . . . . . 23
EVAPORATOR PROBE . . . . . . . . . . . . . . . . . . 24
EXPANSION VALVE . . . . . . . . . . . . . . . . . . . . 25
FILTER-DRIER ASSEMBLY . . . . . . . . . . . . . . . 26
HEATER A/C UNIT HOUSING . . . . . . . . . . . . . 26
HEATER CORE . . . . . . . . . . . . . . . . . . . . . . . . 26
HEATER HOSES . . . . . . . . . . . . . . . . . . . . . . . 28
LIQUID LINE . . . . . . . . . . . . . . . . . . . . . . . . . 28
MODE DOOR ACTUATOR . . . . . . . . . . . . . . . . 29
RECIRC DOOR ACTUATOR . . . . . . . . . . . . . . 30
SIDE WINDOW DEMISTER DUCTS . . . . . . . . 29
SUCTION LINE . . . . . . . . . . . . . . . . . . . . . . . . 29
HEATER A/C UNIT RECONDITION . . . . . . . . . 30
GENERAL INFORMATION
INTRODUCTION
The Heater, or Heater and Ai r Condi ti oni ng sys-
tems share many of the same components. Thi s
group wi l l deal wi th both systems together when
component functi on i s common, and separatel y when
they are not.
For proper operati on of the i nstrument panel con-
trol s, refer to the Owners Manual provi ded wi th the
vehi cl e.
Al l vehi cl es are equi pped wi th a common Heater
A/C uni t housi ng assembl y. When the vehi cl e has
onl y a heater system, the evaporator and reci rcul at-
i ng ai r door are omi tted.
An opti onal zone control HVAC uni t i s avai l abl e.
l ated i ndependentl y of each other. The temperature
setti ng can be di fferent from dri vers si de to passen-
ger si de.
NS/GS HEATING AND AIR CONDITIONING 24 - 1
WARNING: WEAR EYE PROTECTION WHEN SER-
VICING THE AIR CONDITIONING REFRIGERANT
SYSTEM. SERIOUS EYE INJURY CAN RESULT
FROM EYE CONTACT WITH REFRIGERANT. IF EYE
CONTACT IS MADE, SEEK MEDICAL ATTENTION
IMMEDIATELY.
DO NOT EXPOSE REFRIGERANT TO OPEN
FLAME. POISONOUS GAS IS CREATED WHEN
REFRIGERANT IS BURNED. AN ELECTRONIC TYPE
LEAK DETECTOR IS RECOMMENDED.
LARGE AMOUNTS OF REFRIGERANT RELEASED
IN A CLOSED WORK AREA WILL DISPLACE THE
OXYGEN AND CAUSE SUFFOCATION.
THE EVAPORATION RATE OF REFRIGERANT AT
AVERAGE TEMPERATURE AND ALTITUDE IS
EXTREMELY HIGH. AS A RESULT, ANYTHING THAT
COMES IN CONTACT WITH THE REFRIGERANT
WILL FREEZE. ALWAYS PROTECT SKIN OR DELI-
CATE OBJECTS FROM DIRECT CONTACT WITH
REFRIGERANT. R-134a SERVICE EQUIPMENT OR
VEHICLE A/C SYSTEM SHOULD NOT BE PRES-
SURE TESTED OR LEAK TESTED WITH COM-
PRESSED AIR.
SOME MIXTURES OF AIR and R-134a HAVE BEEN
DAMAGE.
ANTIFREEZE IS AN ETHYLENE GLYCOL BASE
COOLANT AND IS HARMFUL IF SWALLOWED OR
INHALED. SEEK MEDICAL ATTENTION IMMEDI-
ATELY IF SWALLOWED OR INHALED. DO NOT
STORE IN OPEN OR UNMARKED CONTAINERS.
WASH SKIN AND CLOTHING THOROUGHLY AFTER
COMING IN CONTACT WITH ETHYLENE GLYCOL.
KEEP OUT OF REACH OF CHILDREN AND PETS.
DO NOT OPEN A COOLING SYSTEM WHEN THE
ENGINE IS AT RUNNING TEMPERATURE. PER-
CAUTION: The engine cooling system is designed
to develop internal pressure of 97 to 123 kPa (14 to
18 psi). Allow the vehicle to cool a minimum of 15
minutes before opening the cooling system. Refer
to Group 7, Cooling System.
AIR DISTRIBUTION DUCTS
The ai r di stri buti on ducts for the A/C, Heater,
Defroster, and Second Seati ng Ai r Di stri buti on are
not servi ceabl e i n vehi cl e. The procedures for servi ce
of these ducts are covered i n Group 8E, I nstrument
Panel and Gauges.
The onl y ducts that are servi ceabl e i n the vehi cl e
are the si de wi ndow demi ster ducts and the ducts
that feed the front door outl ets for the fi rst rear pas-
senger(s) seati ng. To servi ce the door ducts refer to
Group 23, Body.
The A/C Pressure Transducer (Fi g. 1) moni tors the
refri gerant gas pressure on the hi gh si de of the sys-
tem. The transducer i s l ocated on the l i qui d l i ne. The
pressure transducer turns off the vol tage to the com-
pressor cl utch coi l when refri gerant gas pressure
drops to l evel s that coul d damage the compressor.
The transducer al so i s used to adjust condenser fan
speeds and wi l l turn off compressor at hi gh refri ger-
ant pressures. The pressure transducer i s a seal ed
factory cal i brated uni t. I t must be repl aced i f defec-
ti ve. O-ri ng repl acement i s requi red whenever the
pressure transducer i s servi ced. Be sure to use the
O-ri ng speci fi ed for the transducer.
A/C SERVICE PORTS
The A/C servi ce port val ve cores are l ocated wi thi n
the A/C l i nes. The Hi gh Si de (Di scharge) val ve ser-
vi ce port i s l ocated on the l i qui d l i ne near the ri ght
strut tower. The Low Si de (Sucti on) val ve servi ce
port i s l ocated on the sucti on l i ne near the compres-
sor.
The Hi gh Si de servi ce port i s a two pi ece port and
i s servi ceabl e. The Low Si de servi ce port i s not ser-
vi ceabl e, and the sucti on l i ne woul d have to be
repl aced.
COMPRESSOR
The A/C compressor for the 2.5L Turbo Di esel , i s
l ocated on the front si de of the engi ne bl ock. I t i s
mounted to the engi ne bl ock by four bol ts. The com-
Fig. 1 A/C Pressure Transducer
24 - 2 HEATING AND AIR CONDITIONING NS/GS
pressor i s dri ven off the back of the power steeri ng
pump. A rubber fl ex coupl i ng transfers the power from
the power steeri ng pump to the compressor cl utch.
COMPRESSOR HIGH-PRESSURE RELIEF VALVE
The Hi gh Pressure Rel i ef Val ve prevents damage
to the ai r condi ti oni ng system i f excessi ve pressure
devel ops. Excessi ve pressure can be caused by con-
denser ai r fl ow bl ockage, refri gerant overcharge, or
ai r and moi sture i n the system.
The hi gh pressure rel i ef val ve vents onl y a smal l
amount of refri gerant necessary to reduce system
pressure and then reseats i tsel f. The majori ty of the
refri gerant i s conserved i n the system. The val ve i s
cal i brated to vent at a pressure of 3450 to 4140 kPa
(500 to 600 psi ). I f a val ve has vented a smal l
amount of refri gerant, i t does not necessari l y mean
the val ve i s defecti ve.
The Hi gh Pressure Rel i ef Val ve i s l ocated on the
compressor mani fol d at the di scharge passage.
CONDENSATE DRAIN
Condensati on from the evaporator housi ng i s
drai ned through the dash panel and on to the
ground. Thi s drai n must be kept open to prevent
water from col l ecti ng i n the bottom of the housi ng.
I f the drai n i s bl ocked condensate cannot drai n,
causi ng water to back up and spi l l i nto the passenger
compartment. I t i s normal to see condensate drai n-
age bel ow the vehi cl e.
ENGINE COOLING SYSTEM REQUIREMENTS
To mai ntai n ampl e temperature l evel s from the
heati ng-A/C system, the cool i ng system must be i n
proper worki ng order. Refer to Group 0, Lubri cati on
and Mai ntenance or Group 7, Cool i ng System of thi s
manual .
The use of a bug screen i s not recommended. Any
obstructi ons forward of the condenser can reduce the
effecti veness of the ai r condi ti oni ng system.
EVAPORATOR PROBE
The Evaporator probe i s l ocated on the HVAC. The
probe prevents evaporator freeze-up by si gnal i ng the
Powertrai n Control Modul e to cycl e the compressor
ON and OFF. The probe moni tors the temperature of
the refri gerant after expansi on.
The evaporator probe i s i nserted i nto the evapora-
tor between the coi l s. The probe i s a seal ed uni t and
cannot be adjusted or repai red. I t must be repl aced i f
found defecti ve.
HANDLING TUBING AND FITTINGS
Ki nks i n the refri gerant tubi ng or sharp bends i n
the refri gerant hose l i nes wi l l greatl y reduce the
capaci ty of the enti re system. Hi gh pressures are pro-
duced i n the system when i t i s operati ng. Extreme
care must be exerci sed to make sure that al l connec-
ti ons are pressure ti ght. Di rt and moi sture can enter
the system when i t i s opened for repai r or repl ace-
ment of l i nes or components. The refri gerant oi l wi l l
absorb moi sture readi l y out of the ai r. Thi s moi sture
wi l l convert i nto aci ds wi thi n a cl osed system.
CAUTION: The system must be completely empty
before opening any fitting or connection in the
refrigeration system. Open fittings with caution
even after the system has been emptied. If any
pressure is noticed as a fitting is loosened,
retighten fitting and evacuate the system again.
A good rule for the flexible hose lines is to keep
the radius of all bends at least 10 times the diame-
ter of the hose. Sharper bends will reduce the flow
of refrigerant. The flexible hose lines should be
routed so they are at least 3 inches (80 mm) from
the exhaust manifold. Inspect all flexible hose lines
to make sure they are in good condition and prop-
erly routed.
The use of correct wrenches when making con-
nections is very important. Improper wrenches or
improper use of wrenches can damage the fittings.
The internal parts of the A/C system will remain
stable as long as moisture-free refrigerant and
refrigerant oil is used. Abnormal amounts of dirt,
moisture or air can upset the chemical stability.
This may cause operational troubles or even seri-
ous damage if present in more than very small
quantities.
When opening a refrigeration system, have every-
thing you will need to repair the system ready. This
will minimize the amount of time the system must
be opened. Cap or plug all lines and fittings as
soon as they are opened. This will help prevent the
entrance of dirt and moisture. All new lines and
components should be capped or sealed until they
are ready to be used.
All tools, including the refrigerant dispensing
manifold, the manifold gauge set, and test hoses
should be kept clean and dry.
HVAC CONTROL MODULE
The HVAC control modul e regul ates the operati on
of the vari ous actuator motors. The actuator motors
are used to move the mode, bl end- ai r, and reci rc.
doors (Fi g. 2).
The control modul e i s i ncl uded i n the A/C control
head l ocated on the i nstrument panel . The control
head i ncl udes the bl ower speed swi tch, rear wi per
and washer operati on, front & rear wi ndow defogger,
reci rcul ati on door operati on, and A/C compressor
operati on i f equi pped. Refer to Group 8E, I nstrument
Panel and Systems for servi ce procedures.
The rear bl ower speed swi tch i s servi ced separatel y
from the control head.
SIDE DOOR HEATER A/C OUTLETS
The dri vers and passenger si de doors have suppl e-
mental ai r outl ets and duct work. The ai r i s chan-
nel ed from the i nstrument panel to the door duct and
ei ther to the l ower fl oor or upper door outl ets (Fi g.
3). The ai r can be adjusted to bl ow on the fi rst rear
passenger seat(s).
SIDE WINDOW DEMISTER
The si de wi ndow demi sters di rect ai r from the
heater assembl y. The outl ets are l ocated on the top
forward corners of the front door panel s (Fi g. 4). The
demi sters operate when the control mode sel ector i s
on FLOOR, MI X or DEFROST setti ng.
SYSTEM AIRFLOW
The system pul l s outsi de (ambi ent) ai r through the
cowl openi ng at the base of the wi ndshi el d. Then i t
goes i nto the pl enum chamber above the heaterA/C
uni t housi ng. On ai r condi ti oned vehi cl es, the ai r
passes through the evaporator. At thi s poi nt the ai r
fl ow can be di rected ei ther through or around the
heater core. Thi s i s done by adjusti ng the bl end- ai r
door wi th the TEMP control on the control head. An
opti onal zone control HVAC control modul e i s avai l abl e.
l ated i ndependentl y of each other. The temperature set-
ti ng can be di fferent from dri vers si de to passenger
si de. After the ai r passes the bl end-ai r door(s), the ai r
fl ow can then be di rected from the Panel , Fl oor, and
Defrost outl ets. Ai r fl ow vel oci ty can be adjusted wi th
the bl ower speed sel ector swi tch on the control head.
Ambi ent ai r i ntake can be shut off by cl osi ng the
reci rcul ati ng ai r door. Thi s wi l l reci rcul ate the ai r
that i s al ready i nsi de the vehi cl e. Thi s i s done by
depressi ng the Reci rc. button on the control head. On
ai r condi ti oned vehi cl es, movi ng the control to Mi x or
Defrost depresses the A/C button and wi l l engage the
compressor. Thi s wi l l send refri gerant through the
evaporator, and remove heat and humi di ty from the
ai r before i t goes through the heater core.
CAUTION: In cold weather, use of the Recirculation
mode may lead to excessive window fogging. The
Recirculation mode is automatically deactivated in
Mix and Defrost modes to improve window clearing
operation.
SYSTEM OIL LEVEL
I t i s i mportant to have the correct amount of oi l i n
the A/C system to ensure proper l ubri cati on of the
compressor. Too l i ttl e oi l wi l l resul t i n damage to the
compressor. Too much oi l wi l l reduce the cool i ng
Fig. 2 HVAC Control Module
Fig. 3 Door Outlets
Fig. 4 Demister Inlet
capaci ty of the system and consequentl y resul t i n
hi gher di scharge ai r temperatures.
NOTE: The oil used in the Denso 2.5L Turbo Diesel
and the Denso 2.0L gasoline engine compressors is
ND-8 PAG R134a refrigerant oil. Only refrigerant oil
of the same type should be used to service the sys-
tem. Do not use any other oil. The oil container
should be kept tightly capped until it is ready for
use. Tightly cap afterwards to prevent contamina-
tion from dirt and moisture. Refrigerant oil will
quickly absorb any moisture it comes in contact
with. Special effort must be used to keep all R-134a
system components moisture-free. Moisture in the
oil is very difficult to remove and will cause a reli-
ability problem with the compressor.
I t wi l l not be necessary to check oi l l evel i n the
compressor or to add oi l unl ess there has been an oi l
l oss. Oi l l oss at a l eak poi nt wi l l be evi dent by the
presence of a wet, shi ny surface around the l eak.
REFRIGERANT OIL LEVEL CHECK
When an ai r condi ti oni ng system i s fi rst assem-
bl ed, al l components (except the compressor) are
refri gerant oi l free. After the system has been
charged wi th R134a refri gerant and operated, the oi l
i n the compressor i s di spersed through the l i nes and
components. The evaporator, condenser, and fi l ter-
dri er wi l l retai n a si gni fi cant amount of oi l , refer to
the Refri gerant Oi l Capaci ti es chart. When a compo-
nent i s repl aced, the speci fi ed amount of refri gerant
oi l must be added. When the compressor i s repl aced,
the amount of oi l that i s retai ned i n the rest of the
system must be drai ned from the repl acement com-
pressor. When a l i ne or component has ruptured and
oi l has escaped, the compressor shoul d be removed
and drai ned. The compressor i s drai ned through the
sucti on port or by removi ng the sump bol t on top of
the compressor, refer to Compressor Removal and
I nstal l ati on procedures. The fi l ter-dri er must be
repl aced al ong wi th the ruptured part. The oi l capac-
i ty of the system, mi nus the amount of oi l sti l l i n the
remai ni ng components, can be measured and poured
i nto the sucti on port of the compressor.
Exampl e: The evaporator retai ns 50 ml (1.7 oz.).
The condenser retai ns 30 ml (1 oz) of oi l , and system
capaci ty may be 220 ml (7.40 oz) of oi l .
220 ml mi nus 90 ml = 130 ml (4.40 oz.).
CAUTION: The refrigerant oil used in a R-134a A/C
system is unique. Use only oils which were designed
to work with R-134a refrigerant. The oil designated
for the Denso 2.5L Turbo Diesel and Denso 2.0L gas-
oline engine compressors is ND-8 PAG compressor
oil. For gasoline vehicles still using R-12 refrigerant,
use ND8 PAG compressor oil.
SERVICING REFRIGERANT OIL LEVEL
(2) Remove refri gerant l i nes from A/C compressor.
(3) Remove compressor from vehi cl e.
(4) From sucti on port on top of compressor, drai n
refri gerant oi l from compressor.
(5) Add system capaci ty mi nus the capaci ty of
components that have not been repl aced through suc-
ti on port on compressor. Refer to the Refri gerant Oi l
Capaci ty Chart.
(6) I nstal l compressor, connect refri gerant l i nes,
evacuate, and charge refri gerant system.
COOLDOWN TEST
GENERAL INFORMATION
I f the HVAC control modul e i s repl aced, the Cal i -
brati on Di agnosti c and Cool down tests wi l l need to
be performed. Once thi s group of tests have success-
ful l y passed, they can be performed i ndi vi dual l y. The
engi ne must be runni ng duri ng the test to provi de
hot cool ant for the heater, A/C compressor operati on
and to assure that the actuators are cal i brated cor-
rectl y. The HVAC control modul e i s capabl e of trou-
bl eshooti ng the system i n approxi matel y 120 seconds.
I f a condi ti on i s detected, an error code i s di spl ayed.
The error code cannot be erased unti l the condi ti on i s
repai red and the di agnosti c test i s performed. Check
wi re before repl aci ng components, refer to Group 8W,
Wi ri ng Di agrams.
CAUTION: Do not remove the actuators from the
Heater-A/C unit assembly with power applied.
Removal should only be done with the Ignition OFF.
The actuators have no mechanical stops to limit the
travel. If the actuator rotates and is not connected to
the unit assembly, it will become out of calibration.
ACTUATOR CALIBRATION
Mode, Bl end and Zone (i f equi pped) door cal i bra-
ti on compensates for mechani cal vari ati ons i n the
COMPONENT ML OZ
Compressor 135 ml 4.5 oz
Filter-Drier 30 ml 1.0 oz
Condenser 30 ml 1.0 oz
Evaporator 50 ml 1.7 oz
actuators, HVAC control modul e and i ts l i nkages. I n-
vehi cl e cal i brati on can be entered from the control s
front panel . I f the REAR WI PE and I NTERMI T-
TENT LEDs fl ash si mul taneousl y when I gni ti on i s
cycl ed ON, the actuators have not been cal i brated or
duri ng the previ ous cal i brati on a fai l ure occurred
(Fi g. 5) and (Fi g. 6). Di agnosti cs wi l l al ways occur
duri ng Cal i brati on Di agnosti c and Cool down test.
DIAGNOSTICS
Duri ng the Actuator cal i brati on, di agnosti cs are
performed on the actuators and evaporator tempera-
ture Fi n Sensor. Once di agnosti cs are compl eted the
REAR WI PER and I NTERMI TTENT LEDs wi l l fl ash
to i ndi cate ei ther a successful cal i brati on or the
appropri ate fai l code(s). At thi s ti me manual testi ng
of the Bl end, Mode and Dri ver (i f equi pped) potenti -
ometers can be performed. I f a fai l ure i s detected
duri ng Di agnosti cs a faul t wi l l be set i n the control .
When I gni ti on i s cycl ed OFF and then ON or Di ag-
nosti cs i s aborted, the REAR WI PER and I NTER-
MI TTENT LEDs wi l l fl ash si mul taneousl y showi ng
that a fai l ure has occurred. The control wi l l not i ndi -
cate the fai l code, but onl y that a fai l ure had
occurred duri ng the l ast di agnosti cs test. The onl y
way to cl ear the fai l ure codes i s repeat the Cal i bra-
ti on Di agnosti c and Cool down test, after al l repai rs
are compl eted.
COOLDOWN TEST
Thi s test has been desi gned for performance test-
i ng of the A/C system at the manufacturi ng faci l i ty. I f
the HVAC control modul e i s repl aced, the Cool down
test wi l l occur duri ng Cal i brati on test. Cool down wi l l
not occur on Heater Onl y uni ts. Duri ng the Cool down
test the control wi l l moni tor the temperature of the
Fi n Sensor. The A/C system must be abl e to bri ng the
evaporator temperature down a predetermi ned mi ni -
mum amount i n l ess than 2 mi nutes.
CODES
See chart for defi ni ti on of fl ashi ng LEDs. I f no
probl ems are found, the control functi ons normal l y.
CALIBRATION/DIAGNOSTICS TEST ENTRY
TO INITIATE TESTS:
equi pped)
Depress WASH and REAR WI PER button si mul -
taneousl y for 5 Seconds (Unti l al l LEDs l i ght)
RESULTS:
Cal i brati on Test i s runni ng when REAR WI PER
and I NTERMI TTENT are al ternatel y fl ashi ng.
Cool down test i s runni ng i f A/C and RECI RC are
al ternatel y fl ashi ng.
Acceptabl e resul ts i s REAR WI PER LED i s the
onl y LED fl ashi ng. Push Rear Wi per to exi t.
After al l tests have passed, Cal i brati on Di agnos-
ti cs and Cool down can be run separatel y.
Fig. 6 Radio Bezel and HVAC Control, Rear Blower
Motor Switch and Zone Control
COOLDOWN TEST ENTRY
TO INITIATE TESTS:
equi pped)
Depress WASH and A/C si mul taneousl y for 5
Seconds
NOTE: Prior to start of test, If the evaporator is
already cold, the system will fail test. To correct,
operate system with A/C OFF and the blower motor
ON high for three minutes prior to starting test.
RESULTS:
Cool down Test i s runni ng when A/C and
RECI RC. are al ternatel y fl ashi ng. I f A/C and
RECI RC. are fl ashi ng si mul taneousl y, Cool down has
fai l ed.
CALIBRATION DIAGNOSTICS AND
COOLDOWN ABORT
Test can be aborted by doi ng one of the fol l owi ng:
Depressi ng Rear Wi ndow Defogger, RECI RC and
Rear Wi per buttons.
Cycl i ng I gni ti on OFF and then ON.
Control wi l l automati cal l y abort after 15 mi n-
utes from the ti me Cal i brati on Di agnosti cs and
Cool down was entered.
The HVAC control modul e wi l l return to normal
operati on or may i ndi cate unsuccessful Cal i brati on
Di agnosti cs or Cool down test by LEDs fl ashi ng
si mul taneousl y.
EEPROM DATA
Cal i brati on Di agnosti cs, Cool down Status and
evaporator temperature Fi n Sensor val ues are stored
i n an EEPROM memory i nternal to the control . The
mi crocomputer wi thi n the HVAC control modul e uses
thi s i nformati on:
To determi ne i f Cool down needs to run
For proper posi ti on of the Heater-A/C uni t
assembl y doors
ACTUATOR CALIBRATION AND
DIAGNOSTICS.
NOTE: Do not run actuators unless they are prop-
erly mounted on the HVAC control module.
Actuator end poi nt cal i brati on takes approxi matel y
60 seconds. The REAR WI PER and I NTERMI TTENT
LEDs wi l l fl ash al ternatel y duri ng the test. The con-
trol wi l l cycl e the Bl end actuator(s) to the Heat stop
fi rst then back to Col d. After the Bl end actuator(s)
have been cal i brated the Mode actuator wi l l be cycl ed
to Defrost and then to Panel . Successful cal i brati on
i s defi ned as actuator travel fal l i ng wi thi n thei r mi n-
i mum and maxi mum l i mi ts.
BLEND/PASSENGER ACTUATOR BACKGROUND
The Bl end/Passenger Actuator can move the tem-
perature door i n two di recti ons. When the vol tage at
Pi n 12 of the control modul e i s hi gh, about 11.5 vol ts,
and the vol tage at Pi n 17 i s l ow, about 1.5 vol ts, the
door wi l l move towards the Heat posi ti on. When Pi n
17 i s Hi gh and Pi n 12 i s Low the door wi l l move
towards the Col d posi ti on. When both Pi ns are hi gh
or both Pi ns are l ow, the actuator wi l l not move. The
Bl end/Passenger feedback si gnal i s a vol tage si gnal
that i s suppl i ed by the actuator to the control . The
si gnal wi l l be about 4.0 vol ts i n the Heat posi ti on
and 1.0 vol t i n the Col d posi ti on. As the posi ti on of
the Bl end/Passenger actuator changes, so wi l l the
feedback si gnal . The feedback si gnal i s necessary for
the correct posi ti oni ng of the temperature door.
DRIVER ACTUATOR BACKGROUND
The Dri ver Actuator can move the temperature
door i n two di recti ons. When the vol tage at Pi n 15 of
the control modul e i s hi gh, about 11.5 vol ts, and the
vol tage at Pi n 13 i s l ow, about 1.5 vol ts the door wi l l
LEDS PASS/FAIL
CORRECTIVE
ACTION
NO LEDS
FLASHING-
NORMAL
OPERATION
PASSED
CALIBRATION,
DIAGNOSTICS
AND
COOLDOWN
NONE
REAR WIPER
AND
INTERMITTENT
LEDS FLASH
SIMULTANEOUSLY
FAILED
CALIBRATION
DIAGNOSTICS
RUN
CALIBRATION
TEST
A/C AND RECIRC
LEDS FLASH
SIMULTANEOUSLY
FAILED
COOLDOWN
RUN
COOLDOWN
TEST
REAR WIPER
AND
INTERMITTENT
LEDS ARE
FLASHING
SIMULTANEOUSLY
A/C AND RECIRC
LEDS ARE
FLASHING
SIMULTANEOUSLY
FAILED
CALIBRATION,
DIAGNOSTICS
AND FAILED
COOLDOWN
TEST
RUN
CALIBRATION
TEST
move towards the Col d posi ti on. When Pi n 13 i s Hi gh
and Pi n 15 i s Low the door wi l l move towards the
Heat posi ti on. When both Pi ns are hi gh or when both
Pi ns are l ow, the actuator wi l l not move. The Dri ver
4.0 vol ts i n the Heat posi ti on and 1.0 vol t i n the Col d
posi ti on. As the posi ti on of the Dri ver Actuator
temperature door.
MODE ACTUATOR BACKGROUND
The Mode actuator can move the mode door i n two
di recti ons. When the vol tage at Pi n 18 of the control
modul e i s hi gh, about 11.5 vol ts, and the vol tage at
Pi n 12 i s l ow, about 1.5 vol ts the door wi l l move
towards the Panel posi ti on. When Pi n 12 i s Hi gh and
Pi n 18 i s Low the door wi l l move towards the Defrost
posi ti on. When both Pi n are hi gh or when both Pi ns
are l ow, the actuator wi l l not move. The Mode door
4.5 vol ts i n the Panel posi ti on and 0.5 vol ts i n the
Defrost posi ti on. As the posi ti on of the Mode actuator
mode door.
FAIL CODES/LEVEL DISPLAY
Fai l Codes/Level are di spl ayed usi ng the REAR
WI PER and I NTERMI TTENT LEDs fl ashi ng i n the
sequence i ndi cated bel ow. The REAR WI PER LED
represents the Level and the I NTERMI TTENT LED
represents the Val ue. After Cal i brati on/Di agnosti cs i s
compl eted, the control wi l l begi n fl ashi ng Level 1
codes. Depressi ng the WASH button wi l l cycl e to
Level 2, depressi ng WASH agai n wi l l cycl e to Level 3.
Each ti me the WASH button i s depressed wi l l cycl e
to the next l evel . After Level 5 i s reached, you wi l l
cycl e back to Level 1. I f the Control i s a Heater Onl y
you wi l l onl y cycl e from Level s 1 to 3.
TEMPERATURE AND MODE POTENTIOMETER
DIAGNOSTICS
The Temperature and Mode Potenti ometer can be
tested after cal i brati on i s compl ete by pressi ng the
WASH button and cycl i ng to Level s 2, 3 or 5 as di s-
pl ayed by the REAR WI PER LED. On Heater Onl y
uni ts you can onl y cycl e to Level s 2 and 3. I n each
i ndi vi dual test the I NTERMI TTENT LED fl ash rate
wi l l change as the Temperature or Mode potenti ome-
ter i s moved from one end to the other, see Potenti -
ometer vs. Posi ti on and Fl ash Rate tabl e.
EVAPORATOR PROBE TEMPERATURE
DIAGNOSTICS
The evaporator probe can be tested by usi ng the
I NTERMI TTENT LED to di spl ay the actual temper-
ature the sensor i s readi ng. The HVAC control mod-
ul e can onl y di spl ay temperatures from 1 to 99
degrees. To read the temperature, perform the fol l ow-
i ng:
Set Bl ower motor to any speed other than OFF
WIPE BUTTON LED
LEVEL DISPLAY
1 FAIL CODES
2 MODE POTENTIOMETER TEST
3 BLEND/PASS. POTENTIOMETER TEST
4 EVAPORATOR PROBE (A/C AND ZONE
UNITS ONLY)
5 DRIVER POTENTIOMETER (ZONE UNITS
ONLY)
LEVEL 1FAILURE CODE VALUES
(INTERMITTENT WIPE BUTTON LED)
CODE DEFINITION
0 PASSED ALL TESTS
DEFROST POSITION
PANEL POSITION
3 BLEND/PASS. ACTUATOR DID NOT
REACH COLD STOP
4 BLEND PASS. ACTUATOR DID NOT
REACH HEAT STOP
5 EVAPORATOR PROBE OPEN
6 EVAPORATOR PROBE SHORTED
7 DRIVER ACTUATOR DID NOT REACH
COLD STOP
8 ZONE/DRIVER ACTUATOR DID NOT
REACH HEAT STOP
9 CONTROL HEAD INTERNAL FAILURE
POTENTIOMETER VS. POSITION
AND FLASH RATE
POTENTIOMETER
INTERMITTENT
LED FASTER
FLASH RATE
INTERMITTENT
LED SLOWER
FLASH RATE
MODE PANEL DEFROST
BLEND/PASS. HOT COLD
DRIVER HOT COLD
Set A/C to ON, i f A/C Cl utch does not engage
make sure Fai l Codes 5 and 6 are cl eared.To cl ear
the error code 5 and 6 the evaporator probe and/or
the wi ri ng repai r needs to be compl eted. Then, press
and hol d the i ntermi ttent wi pe button for 5 seconds.
Run Di agnosti cs (Depress REAR WI PER and
REAR WASH)
When Di agnosti cs i s compl ete, Cycl e to Level 4.
Di spl ay Sequence i s as fol l ows:
REAR WI PER LED wi l l di spl ay the Level
I NTERMI TTENT LED wi l l di spl ay tens di gi t
Short Pause
I NTERMI TTENT LED wi l l di spl ay the ones
di gi t.
The HVAC control modul e wi l l conti nue to cycl e
the Level and then Temperature unti l the l evel i s
changed or Cal i brati on Di agnosti cs and Cool down
test i s exi ted.
HVAC CONTROL DIAGNOSTIC CONDITIONS
For wi ri ng ci rcui ts, wi ri ng connectors, and Pi n
numbers, refer to Group 8W, Wi ri ng Di agrams.
onc e, Intermittent LED not flashing.
The system has passed cal i brati on. Press the Rear
Wi per button to exi t cal i brati on.
onc e, Intermittent LED flashing onc e. The
mode ac tuator did not reac h defrost position.
Move the HVAC control from the defrost to panel
essary.
actuator.
onc e, Intermittent LED flashing twic e. The
mode ac tuator did not reac h panel position.
Move the HVAC control from panel to defrost posi -
ti on, and check Pi n 6 vol tage i t shoul d change from
3.5 - 4.5 vol ts to 0.5 - 1 vol ts. I f vol tage i s OK, go to
Step 2. I f not OK, check for l oose or corroded connec-
tor, open or shorted ci rcui t and repai r as necessary.
i n the correct cam track or bi ndi ng. I f OK, go to Step
3. I f not OK, repai r as necessary.
actuator.
onc e, Intermittent LED flashing three times.
not reac h c old stop.
used.
vol tage. Move the HVAC control from the col d to hot
essary.
(3) Remove actuator, and check i f gear pi ns are i n
the correct cam track or bi ndi ng. I f OK, go to Step 4.
I f not OK, repai r as necessary.
actuator.
onc e, Intermittent LED flashing four times.
not reac h hot stop.
used.
vol tage. Move the HVAC control from hot to col d
posi ti on and check Pi n 5 vol tage i t shoul d change
from 3.5 -4.5 vol ts 0.5 - 1.5 vol ts. I f vol tage i s OK, go
sary.
actuator.
onc e, Intermittent LED flashing five times.
The evaporator probe is open.
go to Step 2. I f not OK, i f greater than 4.75 vol ts
check for l oose or corroded connector, open ci rcui t
ground, I f OK, go to Step 3. I f not OK, check for l oose
or corroded connector, open or shorted ci rcui t and
Evaporator Probe.
onc e, Intermittent LED flashing six times. The
evaporator probe is shorted.
go to Step 2. I f l ess than 0.1 vol ts, check for l oose or
corroded connector, open or shorted ci rcui t and repai r
as necessary.
ground, I f OK, go to Step 3. I f not OK, check for
shorted ci rcui t and repai r as necessary.
Evaporator Probe
onc e, Intermittent LED flashing seven times.
system did not reac h c old stop.
used.
tery vol tage. Move the HVAC control from col d to the
hot posi ti on, check Pi n 4 vol tage i t shoul d change
from 0.5 - 1.5 vol ts 3.5 - 4.5 vol ts. I f vol tage i s OK, go
sary.
(4) Check for bi ndi ng doors, i f door are bi ndi ng
repai r as necessary. I f gears and door are OK, repl ace
actuator.
onc e, Intermittent LED flashing eight times.
system did not reac h hot stop.
used.
tery vol tage. Move the HVAC control from hot to col d
posi ti on, Pi n 4 vol tage i t shoul d change from 3.5 - 4.5
vol ts to 0.5 - 1.5 vol ts. I f vol tage i s OK, go to Step 3.
I f not OK, check for l oose or corroded connector, open
or shorted ci rcui t and repai r as necessary.
actuator.
onc e, Intermittent LED flashing nine times.
The HVAC c ontrol module, has a internal
failure.
(1) Repl ace the HVAC control modul e.
After c alibration and testing the A/C and
RECIRC LED flashing simultaneously. Failed
Cooldown test.
(1) Determi ne i f the refri gerant system i s operat-
i ng correctl y:
Check the outl et ai r temperature
Feel the compressor sucti on pl umbi ng, i s i t hot?
(2) I f not OK, go to Step 3. I f OK, repeat the Cal -
i brati on Di agnosti c and Cool down test.
(3) I f system does not seem to be operati ng cor-
rectl y, perform di agnosti cs for poor performance:
Low refri gerant charge
No charge
Compressor not operati ng
Veri fy that the test was done wi th the evaporator
at room temperature. The test consi sts of starti ng
the compressor and measuri ng the ti me i t takes for
the evaporator temperature to fal l 7C (20F). I f the
compressor has been runni ng, the evaporator i s col d
al ready and wi l l not be capabl e of fal l i ng 7C (20F).
I f the test was run wi th a col d evaporator, turn A/C
off and turn the bl ower motor swi tch to hi gh posi ti on
for 3 to 5 mi nutes ti l l the evaporator i s to room tem-
perature. Then repeat the Cal i brati on Di agnosti c and
Cool down test.
I f refri gerant system i s performi ng properl y and
the system wi l l not pass test. Repeat the Cal i brati on
Di agnosti c and Cool down test to determi ne i f the
evaporator temperature FI N sensor has devel oped an
open or a short ci rcui t. I f the HVAC control modul e
sti l l passes Cal i brati on test, veri fy Cool down test
manual l y wi th a pocket thermometer. The outl et ai r
temperature must drop at l east 7C (20F) wi thi n
two mi nutes. I f the vehi cl e passes wi th the manual
thermometer, take HVAC control to l evel 4 (evapora-
tor probe temperature readout) and repeat the
Cool down test. Ensure the evaporator i s at room tem-
perature before starti ng test. Check i f evaporator
probe wi l l drop the temperature 7C (20F) i n two
mi nutes. I f the Evaporator Probe i s found to be
faul ty, check that the sensor i s posi ti oned i n the
evaporator fi ns properl y. I f not, correct and repeat
test. I f OK, repl ace the evaporator probe.
Once the repai rs are compl eted, repeat the Cal i bra-
A/C PERFORMANCE TEST
The ai r condi ti oni ng system i s desi gned to remove
heat and humi di ty from the ai r enteri ng the passen-
ger compartment. The evaporator, l ocated i n the
heater A/C uni t, i s cool ed to temperatures near the
freezi ng poi nt. As warm damp ai r passes over the
fi ns i n the evaporator, moi sture i n the ai r condenses
to water, dehumi di fyi ng the ai r. Condensati on on the
evaporator fi ns reduces the evaporators abi l i ty to
absorb heat. Duri ng peri ods of hi gh heat and humi d-
i ty, an ai r condi ti oni ng system wi l l be l ess effecti ve.
Wi th the i nstrument control set to RECI RC, onl y ai r
from the passenger compartment passes through the
evaporator. As the passenger compartment ai r dehu-
mi di fi es, A/C performance l evel s ri se.
PERFORMANCE TEST PROCEDURE
group before proceedi ng wi th thi s procedure. Ai r tem-
perature i n test room and on vehi cl e must be 21 C
(70F) mi ni mum for thi s test.
(1) Connect a tachometer and mani fol d gauge set.
(2) Set control to A/C, RECI RC, and PANEL, tem-
perature l ever on ful l cool and bl ower on hi gh.
(3) Start engi ne and hol d at 1000 rpm wi th A/C
cl utch engaged.
(4) Engi ne shoul d be warmed up wi th doors and
wi ndows cl osed.
(5) I nsert a thermometer i n the l eft center A/C
outl et and operate the engi ne for fi ve mi nutes. The
A/C cl utch may cycl e dependi ng on ambi ent condi -
ti ons.
(6) Wi th the A/C cl utch engaged, compare the di s-
charge ai r temperature to the A/C Performance Tem-
peratures chart (Fi g. 7).
(7) I f the di scharge ai r temperature fai l s to meet
the speci fi cati ons i n the performance temperature
chart. Refer to the Refri gerant Servi ce Procedures for
further di agnosi s.
The work area temperature must not be bel ow
10C (50F) to test the compressor cl utch ci rcui t.
Before starti ng to test the transducer ensure that the
wi re connector i s cl ean of corrosi on and connected
properl y.
(1) Wi th gear sel ector i n park or neutral and park
brake set, start engi ne and al l ow to i dl e.
(2) I nstal l scan tool (DRB):
Go to mai n menu
Sel ect stand al one scan tool (DRB)
Sel ect refer to the proper year di agnosti cs
Sel ect cl i mate control
Sel ect sensor di spl ay
Sel ect A/C hi gh si de vol ts
For A/C system to operate a vol tage between .451
(Low Pressure Cutout) to 4.519 (Hi gh Pressure Cut-
out i s requi red. Vol tages outsi de thi s range i ndi cate a
l ow or hi gh pressure condi ti on and will not al l ow
the compressor to cycl e.
The fol l owi ng chart denotes vol tages and the
appropri ate condi ti on(s):
VIBRATION AND/OR NOISE DIAGNOSIS
The bl ower speed swi tch, i n conjuncti on wi th the
resi stor bl ock, suppl i es the bl ower motor wi th vari ed
vol tage.
CAUTION: Stay clear of the blower motor and resis-
tor block (Hot). Do not operate the blower motor
with the resistor block removed from the heater A/C
housing.
Refer to the Bl ower Motor Vi brati on/Noi se chart i n
thi s secti on for di agnosi s.
COMPRESSOR NOISE DIAGNOSIS
Excessi ve noi se whi l e the A/C i s bei ng used, can be
caused by l oose mounts, cl utch, or hi gh operati ng
pressure. Veri fy compressor dri ve bel t condi ti on,
proper refri gerant charge and head pressure before
compressor repai r i s performed.
The ai r condi ti oni ng compressor cl utch el ectri cal
ci rcui t i s control l ed by the Powertrai n Control Mod-
ul e. I t i s l ocated i n the engi ne compartment outboard
of the battery.
I f the compressor cl utch does not engage veri fy
refri gerant charge.
I f the compressor cl utch sti l l does not engage check
for battery vol tage at the pressure transducer l ocated
on the l i qui d l i ne. I f vol tage i s not detected, refer to:
Group 8W, Wi ri ng di agrams.
Powertrai n Di agnosti c Procedures manual for
di agnosti c i nformati on.
I f vol tage i s detected at the pressure transducer,
connect pressure transducer and check for battery
vol tage between the compressor cl utch connector ter-
mi nal s.
I f vol tage i s detected, perform A/C Cl utch Coi l
Tests.
TESTS
(1) Veri fy battery state of charge. (Test i ndi cator i n
battery shoul d be green).
(2) Connect an ampmeter (0-10 ampere scal e) i n
seri es wi th the cl utch coi l termi nal . Use a vol tmeter
(0-20 vol t scal e) wi th cl i p l eads measuri ng vol tage
across the battery and A/C cl utch.
(3) Wi th A/C control i n A/C mode and bl ower at
l ow speed, start the engi ne and run at normal i dl e.
(4) The A/C cl utch shoul d engage i mmedi atel y and
the cl utch vol tage shoul d be wi thi n two vol ts of the
battery vol tage. I f the A/C cl utch does not engage,
test the fuse.
(5) The A/C cl utch coi l i s acceptabl e i f the current
draw i s 2.0 to 3.7 amperes at 11.5-12.5 vol ts at cl utch
coi l . Thi s i s wi th the work area temperature at 21C
(70F). I f vol tage i s more than 12.5 vol ts, add el ectri -
cal l oads by turni ng on el ectri cal accessori es unti l
vol tage reads bel ow 12.5 vol ts.
Fig. 7 A/C PERFORMANCE TEMPERATURES
VOLTAGE CONDITION
0 Transducer faulty or no voltage
from PCM
.150 to .450 Transducer good/Low Pressure
Cutout condition
.451 to 4.519 Normal operating condition
4.520 to 4.850 Transducer good/High
Pressure Cutout condition
5 Transducer faulty
Blower Motor Noise/Vibration Diagnosis
(6) I f coi l current reads zero, the coi l i s open and
shoul d be repl aced. I f the ammeter readi ng i s 4
amperes or more, the coi l i s shorted and shoul d be
repl aced. I f the coi l vol tage i s not wi thi n two vol ts of
the battery vol tage, test cl utch coi l feed ci rcui t for
excessi ve vol tage drop.
EXPANSION VALVE
TESTS
NOTE: Expansion valve tests should be performed
after compressor tests.
group. The work area and vehi cl e temperature must
be 21C to 27C (70F to 85F). To test the expansi on
val ve:
NOTE: Liquid CO2 is required to test the expansion
valve. It is available from most welding supply facil-
ities. CO2 is also available from companies which
service and sell fire extinguishers.
(1) Connect a chargi ng stati on or mani fol d gauge
set to the refri gerant system servi ce ports. Veri fy the
refri gerant charge l evel .
(2) Cl ose al l doors, wi ndows and vents to the pas-
senger compartment.
(3) Set heater A/C control to A/C, ful l heat,
FLOOR, and hi gh bl ower.
(4) Start the engi ne and al l ow to i dl e (1000 rpm).
After the engi ne has reached runni ng temperature,
al l ow the passenger compartment to heat up. Thi s
wi l l create the need for maxi mum refri gerant fl ow
i nto the evaporator.
(5) I f the refri gerant charge i s suffi ci ent, di scharge
(hi gh pressure) gauge shoul d read 965 to 1655 kPa (140
to 240 psi ). Sucti on (l ow pressure) gauge shoul d read
140 kPa to 207 kPa (20 psi to 30 psi g). I f system cannot
achi eve proper pressure readi ngs, repl ace the expan-
si on val ve. I f pressure i s correct, proceed wi th test.
WARNING: PROTECT SKIN AND EYES FROM CON-
TACTING CO2 PERSONAL INJURY CAN RESULT.
(6) I f sucti on si de l ow pressure i s wi thi n speci fi ed
range, freeze the expansi on val ve control head for 30
seconds. Use a super col d substance (l i qui d CO2). Do
not spray R-134a Refrigerant on the expansion
valve for this test. Sucti on si de l ow pressure shoul d
drop by 10 psi . I f not, repl ace expansi on val ve.
(7) Al l ow expansi on val ve to thaw. The l ow pres-
sure gauge readi ng shoul d stabi l i ze at 140 kPa to
240 kPa (20 psi to 30 psi g). I f not, repl ace expansi on
val ve.
(8) When expansi on val ve test i s compl ete, test
A/C overal l performance. Remove al l test equi pment
HEATER PERFORMANCE TEST
PRE-DIAGNOSTIC PREPARATIONS
group before performi ng the fol l owi ng procedures.
Check the cool ant l evel , dri ve bel t tensi on, vacuum
l i ne connecti ons, radi ator ai r fl ow and fan operati on.
Start engi ne and al l ow to warm up to normal tem-
perature.
WARNING: DO NOT REMOVE RADIATOR CAP
WHEN ENGINE IS HOT, PERSONAL INJURY CAN
RESULT.
I f vehi cl e has been run recentl y, wai t 15 mi nutes
before removi ng cap. Pl ace a rag over the cap and
turn i t to the fi rst safety stop. Al l ow pressure to
escape through the overfl ow tube. When the system
stabi l i zes, remove the cap compl etel y.
MAXIMUM HEATER OUTPUT: TEST AND
ACTION
Engi ne cool ant i s provi ded to the heater system by
two 16 mm (5/8 i nch i nsi de di ameter) heater hoses.
Wi th engi ne i dl i ng at normal runni ng temperature,
set the control to maxi mum heat, fl oor, and hi gh
bl ower setti ng. Usi ng a test thermometer, check the
ai r temperature comi ng from the fl oor outl ets, refer
to Temperature Reference chart.
I f the fl oor outl et ai r temperature i s i nsuffi ci ent,
refer to Group 7, Cool i ng Systems for speci fi cati ons.
Both heater hoses shoul d be HOT to the touch (cool -
ant return hose shoul d be sl i ghtl y cool er than the
suppl y hose). I f cool ant return hose i s much cool er
than the suppl y hose, l ocate and repai r engi ne cool -
ant fl ow obstructi on i n heater system.
TEMPERATURE REFERENCE CHART
AMBIENT TEMP.
MINIMUM FLOOR
OUTLET TEMP.
CELSIUS FAHRENHEIT CELSIUS FAHRENHEIT
15.5 60 62.2 144
21.1 70 63.8 147
26.6 80 65.5 150
32.2 90 67.2 153
POSSIBLE LOCATIONS OR CAUSE OF
OBSTRUCTED COOLANT FLOW
(1) Pi nched or ki nked heater hoses.
(2) I mproper heater hose routi ng.
(3) Pl ugged heater hoses or suppl y and return
ports at cool i ng system connecti ons, refer to Group 7,
Cool i ng System.
(4) Pl ugged heater core.
(5) Ai r l ocked heater core.
(6) I f cool ant fl ow i s veri fi ed and outl et tempera-
ture i s i nsuffi ci ent, a mechani cal probl em may exi st.
POSSIBLE LOCATION OR CAUSE OF
INSUFFICIENT HEAT
(1) Obstructed cowl ai r i ntake.
(2) Obstructed heater system outl ets.
(3) Bl end-ai r door not functi oni ng properl y.
TEMPERATURE CONTROL
I f temperature cannot be adjusted wi th the TEMP
l ever on the control panel , the fol l owi ng coul d requi re
servi ce:
(1) Bl end-ai r door bi ndi ng.
(2) Faul ty bl end-ai r door motor.
(3) I mproper engi ne cool ant temperature.
(4) Faul ty I nstrument Panel Control .
SYSTEM CHARGE LEVEL TEST
The procedure bel ow shoul d be used to check
and/or fi l l the refri gerant charge i n the ai r condi ti on-
i ng system.
NOTE: The amount of R134a refrigerant that the air
conditioning system holds is 0.96 kg (34 oz. or 2.13
lbs.).
NOTE: Low Charge, condition may be described
as:
Loss of A/C performance
Fog from A/C outlets
evaporator may have a HISS sound
There are two di fferent ways the system can be
tested:
Wi th a scan tool (DRB), thermocoupl e and the
Charge Determi nati on Graph. Use the scan tool
(DRB) di agnosti c topi c: Engi neSystem Moni tors, A/C
Pressure.
Usi ng a mani fol d gauge set, a thermocoupl e and
the Charge Determi nati on Graph.
I t i s recommended to use the gauges or recl ai m/re-
cycl e equi pment.
REQUIREMENTS TO DISCHARGE R-134a SYSTEM. IF
ACCIDENTAL SYSTEM DISCHARGE OCCURS, VEN-
TILATE WORK AREA BEFORE RESUMING SERVICE.
R-134a SERVICE EQUIPMENT OR VEHICLE A/C
SYSTEM SHOULD NOT BE PRESSURE TESTED OR
LEAK TESTED WITH COMPRESSED AIR. SOME
MIXTURES OF AIR/R-134a HAVE BEEN SHOWN TO
BE COMBUSTIBLE AT ELEVATED PRESSURES.
THESE MIXTURES ARE POTENTIALLY DANGER-
OUS AND MAY RESULT IN FIRE OR EXPLOSION
CAUSING INJURY OR PROPERTY DAMAGE.
(1) Establ i sh your preferred method of measuri ng
l i qui d l i ne pressure. Use a mani fol d gauge set or a
DRB scan tool .
(2) Attach a cl amp-on thermocoupl e (Professi onal
Servi ce Equi pment 66-324-0014 or 80PK-1A) or equi v-
al ent to the l i qui d l i ne. I t must be pl aced as cl ose to
the A/C Pressure Transducer as possi bl e to observe l i q-
ui d l i ne temperature. Refer to Thermocoupl e Probe i n
thi s secti on for more i nformati on on probe.
(3) The vehi cl e must be i n the fol l owi ng modes:
Transaxl e i n Park
A/C Control s Set to Outsi de Ai r
Panel Mode
Ful l Cool
Hi gh Bl ower motor, (vehi cl e equi pped wi th rear
A/C turn rear bl ower motor ON HI GH)
A/C Button i n the ON posi ti on
Vehi cl e Wi ndows Open.
Reci rc. button turned OFF
(4) Operate system for a coupl e of mi nutes to al l ow
the system to stabi l i ze.
(5) Set system pressure to about 1793 kPa (260
psi ) by pl aci ng a pi ece of cardboard over part of the
front si de of the condenser. To pl ace cardboard prop-
erl y, remove the upper radi ator-condenser cover.
I nsert cardboard between condenser and radi ator
front. Thi s wi l l mai ntai n a constant pressure.
(6) Observe Li qui d Li ne pressure and Li qui d l i ne
temperature. Usi ng the Charge Determination
Chart determi ne where the system i s currentl y oper-
ati ng. I f the system i s i n the undercharged regi on,
ADD 0.057 Kg. (2 oz.) to the system and recheck
readi ngs. I f the system i s i n the overcharged regi on,
RECLAI M 0.057 Kg. (2 oz.) from the system and
recheck readi ngs. Conti nue thi s process unti l the sys-
tem readi ngs are i n the proper charge area on the
Charge Determination Chart.
(7) The same procedure can be performed usi ng
the scan tool (DRB). To determi ne l i qui d l i ne pres-
sure, attach the scan tool , go to System Moni -
torsA/C Pressure. Observe l i qui d l i ne pressure from
A/C Pressure Transducer on di gi tal di spl ay and di gi -
tal thermometer. Refer to Charge Determination
Chart and determi ne where the system i s operati ng.
SERVICE PROCEDURES
R-134a REFRIGERANT
Thi s vehi cl e uses a new type of refri gerant cal l ed
R-134a. I t i s a non-toxi c, non-fl ammabl e, cl ear col or-
l ess l i quefi ed gas.
R-134a refri gerant i s not compati bl e wi th R-12
refri gerant i n an ai r condi ti oni ng system. Even a
smal l amount of R-12 i n a R-134a system coul d cause
compressor fai l ure, refri gerant oi l to sl udge and/or
poor performance. Never add any other type of
refrigerant to a system designed to use R-134a
refrigerant. System failure will occur.
The hi gh pressure servi ce port i s l ocated on the l i q-
ui d l i ne near the strut tower. The l ow pressure ser-
vi ce port i s l ocated on the sucti on l i ne near the
compressor mani fol d.
When servi ci ng a system, i t i s requi red that an ai r
condi ti oni ng chargi ng recovery/recycl i ng machi ne be
used (Fi g. 8). Contact an automoti ve servi ce equi p-
ment suppl i er for proper equi pment. Refer to the
operati ng i nstructi ons provi ded wi th the equi pment
for proper operati on.
A mani fol d gauge set (Fi g. 9) must al so be used i n
conjuncti on wi th the chargi ng and/or recovery/recy-
cl i ng devi ce. Onl y use gauges that have not been
used for R-12. The servi ce hoses on the gauge set
shoul d have manual (turn wheel ) or automati c back
fl ow val ves at the servi ce port connector ends. Thi s
wi l l prevent refri gerant R-134a from bei ng rel eased
i nto the atmosphere.
R-134a refri gerant requi res a speci al type of com-
pressor oi l . When addi ng oi l , make sure to use the oi l
that i s speci fi ed on the under hood l abel .
Due to the di fferent characteri sti cs of R-134a i t
requi res al l new servi ce procedures.
Charge Determination Chart
Fig. 8 Refrigerant Recovery/Recycling Station
(Typical)
The use of R-134a wi l l have a posi ti ve envi ronmen-
tal i mpact due to i ts zero ozone depl eti on and l ow
gl obal warmi ng i mpact.
CHARGING REFRIGERANT SYSTEM
CAUTION: Do not overcharge refrigerant system,
as excessive compressor head pressure can cause
noise and system failure.
After the system has been tested for l eaks and
evacuated, a refri gerant (R-134a) charge can be
i njected i nto the system.
(1) Connect mani fol d gauge set.
(2) Measure refri gerant 0.96 kg (34 oz. or 2.13 l b.)
and heat to 52C (125F) wi th the chargi ng stati on.
Refer to the i nstructi ons provi ded wi th the equi p-
ment bei ng used.
(3) Open the sucti on and di scharge val ves. Open
the charge val ve to al l ow the heated refri gerant to
fl ow i nto the system. When the transfer of refri ger-
ant has stopped, cl ose the sucti on and di scharge
val ve.
(4) I f al l of the charge di d not transfer from the
di spensi ng devi ce, run engi ne at a hi gh i dl e (1400
rpm). Set the A/C control to A/C, l ow bl ower speed,
and open wi ndows. I f the A/C compressor does not
engage, test the compressor cl utch control ci rcui t and
correct any fai l ure. Refer to Group 8W, Wi ri ng Di a-
grams.
(5) Open the sucti on val ve to al l ow the remai ni ng
refri gerant to transfer to the system.
WARNING: TAKE CARE NOT TO OPEN THE DIS-
CHARGE (HIGH-PRESSURE) VALVE AT THIS TIME.
(6) Cl ose al l val ves and test the A/C system perfor-
mance.
(7) Di sconnect the chargi ng stati on or mani fol d
gauge set. I nstal l the servi ce port caps.
EVACUATING REFRIGERANT SYSTEM
NOTE: Special effort must be used to prevent mois-
ture from entering the A/C system oil. Moisture in
the oil is very difficult to remove and will cause a
I f a compressor desi gned to use R-134a refri gerant
i s l eft open to the atmosphere for an extended peri od
of ti me. I t i s recommended that the refri gerant oi l be
drai ned and repl aced wi th new oi l or a new compres-
sor be used. Thi s wi l l el i mi nate the possi bi l i ty of con-
tami nati ng the refri gerant system.
I f the refri gerant system has been open to the
atmosphere, i t must be evacuated before the system
can be fi l l ed. Moi sture and ai r mi xed wi th the refri g-
erant wi l l rai se the compressor head pressure above
acceptabl e operati ng l evel s. Thi s wi l l reduce the per-
formance of the ai r condi ti oner and damage the com-
pressor. Moi sture wi l l boi l at near room temperature
when exposed to vacuum. To evacuate the refri gerant
system:
(1) Connect a sui tabl e chargi ng stati on, refri gerant
recovery machi ne, or a mani fol d gauge set wi th vac-
uum pump to the servi ce ports (Fi g. 10).
(2) Open the sucti on and di scharge val ves and
start the vacuum pump. The vacuum pump shoul d
run a mi ni mum of 45 mi nutes pri or to charge to
el i mi nate al l moi sture i n system. When the sucti on
gauge reads -88 kPa (-26 i n. Hg) vacuum or greater
for 45 mi nutes, cl ose al l val ves and turn off vacuum
pump. I f the system fai l s to reach speci fi ed vacuum,
the refri gerant system l i kel y has a l eak that must be
corrected. I f the refri gerant system mai ntai ns speci -
fi ed vacuum for at l east 30 mi nutes, start the vac-
uum pump, open the sucti on and di scharge val ves.
Then al l ow the system to evacuate an addi ti onal 10
mi nutes.
Fig. 9 Manifold Gauge Set- Typical
(3) Cl ose al l val ves. Turn off and di sconnect the
vacuum pump.
(4) The refri gerant system i s prepared to be
charged wi th refri gerant.
THERMOCOUPLE PROBE
To di agnose the A/C system, a temperature probe i s
requi red to measure l i qui d l i ne temperature. The
cl amp-on type K probe shown i n thi s manual i s avai l -
abl e through the Chrysl er Professi onal Servi ce Equi p-
ment (PSE) program. Thi s probe i s compati bl e wi th
temperature-measuri ng i nstruments that accept Type
K Thermocoupl es and have a mi ni ature connector
i nput. Other temperature probes are avai l abl e through
aftermarket sources. Al l references i n thi s manual wi l l
refl ect the use of the probe made avai l abl e through the
Professi onal Servi ce Equi pment program.
I n order to use the temperature probe, a di gi tal
thermometer wi l l be requi red. I f a di gi tal thermo-
meter i s not avai l abl e, an adapter i s avai l abl e
through the Professi onal Servi ce Equi pment pro-
gram. I t can convert any standard di gi tal mul ti meter
i nto a thermometer. Thi s adapter i s desi gned to
accept any standard K-type thermocoupl e.
I f a di gi tal mul ti meter i s not avai l abl e, i t to can be
ordered through Professi onal Servi ce Equi pment pro-
gram.
BUTTONS
To servi ce HVAC control modul e push buttons that
are sti cki ng, spray between the buttons wi th Mopar
MP-50. The MP-50 i s a al l purpose l ubri cant for
mechani cal and el ectri cal uses. After sprayi ng around
the push buttons wi pe any excess off the radi o bezel
and HVAC control modul e push buttons. Operate the
buttons to ensure that they are operati ng freel y.
Fig. 10 Refrigerant Lines and Port Locations (2.5L Turbo Diesel engine)
SYSTEM LEAK CHECKING
WARNING: R-134a SERVICE EQUIPMENT OR VEHI-
CLE A/C SYSTEM SHOULD NOT BE PRESSURE
TESTED OR LEAK TESTED WITH COMPRESSED
AIR. SOME MIXTURES OF AIR/R-134a HAVE BEEN
DAMAGE.
I f the A/C system i s not cool i ng properl y, determi ne
i f the refri gerant system i s ful l y charged wi th
R-134a. Thi s i s accompl i shed by performi ng a system
Charge Level -Check or Fi l l . I f whi l e performi ng thi s
test A/C l i qui d l i ne pressure i s l ess than 207 kPa (30
psi ) proceed to Empty Refri gerant System Leak Test.
I f l i qui d l i ne pressure i s greater than 207 kPa (30
psi ) proceed to l ow refri gerant l evel l eak test. I f the
refri gerant system i s empty or l ow i n refri gerant
charge, a l eak at any l i ne fi tti ng or component seal i s
l i kel y. A revi ew of the fi tti ngs, l i nes and components
for oi l y resi due i s an i ndi cati on of the l eak l ocati on.
To detect a l eak i n the refri gerant system, perform
one of the fol l owi ng procedures as i ndi cated by the
symptoms.
VICE.
EMPTY REFRIGERANT SYSTEM LEAK TEST
(1) Evacuate the refri gerant system to the l owest
degree of vacuum possi bl e (about 28 i n Hg.). Deter-
mi ne i f the system hol ds a vacuum for 15 mi nutes. I f
vacuum i s hel d, a l eak i s probabl y not present. I f sys-
tem wi l l not mai ntai n vacuum l evel , proceed wi th
thi s procedure.
(2) Prepare a .284 Kg. (10 oz.) refri gerant charge
to be i njected i nto the system.
(3) Connect and di spense .284 Kg. (10 oz.) of
refri gerant i nto the evacuated refri gerant system.
(4) Proceed to step two of Low Refri gerant Level
Leak Test.
LOW REFRIGERANT LEVEL LEAK TEST
(1) Determi ne i f there i s any (R-134a) refri gerant
i n the system. Use the scan tool (DRB) under the
menu Systems SensorsA/C Pressure test or pressure
gauge l i qui d l i ne temperature parti al charge check.
See system charge l evel check or fi l l for procedure.
(2) Posi ti on the vehi cl e i n a wi nd free work area.
Thi s wi l l ai d i n detecti ng smal l l eaks.
(3) Bri ng the refri gerant system up to operati ng
temperature and pressure. Thi s i s done by al l owi ng
the engi ne to run for fi ve mi nutes wi th the system
set to the fol l owi ng:
Transaxl e i n Park
A/C Control s Set i n 100 percent outsi de ai r
Ful l Panel Mode
Bl ower motor ON HI GH
A/C i n the ON posi ti on
Front Wi ndows Open.
Rear Ai r Off (I f Equi pped)
CAUTION: A leak detector designed for R-12 refrig-
erant will not detect leaks in a R-134a refrigerant
system.
(4) Shut off the vehi cl e and wai t 2 to 7 mi nutes.
Then use an El ectroni c Leak Detector that i s
desi gned to detect R-134a type refri gerant and search
for l eaks. Fi tti ngs, l i nes, or components that appear
to be oi l y usual l y i ndi cates a refri gerant l eak. To
i nspect the evaporator core for l eaks, i nsert the l eak
detector probe i nto the reci rcul ati ng ai r door openi ng
or a heat duct.
I f a thorough l eak check has been compl eted wi th-
out i ndi cati on of a l eak, proceed to System Charge
Level -Check or Fi l l .
REMOVAL
(1) Di sconnect the wi re connector at the pressure
transducer.
(2) Usi ng an open end wrench, remove the trans-
ducer from the l i qui d l i ne (Fi g. 11).
INSTALLATION
(1) Repl ace transducer O-ri ng.
A/C SERVICE PORTS
The Hi gh Si de servi ce port i s servi ceabl e, the Low
Si de i s not servi ceabl e.
REMOVAL
(3) Unscrew the Hi gh Si de servi ce port from the
l i qui d l i ne.
(4) Remove O-ri ng
INSTALLATION
Install new O-ring.
BLEND-AIR DOOR ACTUATOR
REMOVAL
The ai r condi ti oni ng system can be equi pped wi th
ei ther a standard, si ngl e bl end-ai r door actuator, or i t
can be equi pped wi th dual actuators. The dual sys-
tem has separate bl end-ai r control s. Thi s al l ows for
separate control of the dri vers si de ai r, and the pas-
senger si de ai r (Fi g. 12).
tems.
(3) Remove bl end-ai r actuator connector.
(4) Remove bl end-ai r actuator (Fi g. 14).
INSTALLATION
nosti c and Cool down test. Repeati ng the test i s nec-
essary to cl ear the faul t codes.
REMOVAL
(1) Remove gl ove box. Refer to Group 8E, I nstru-
ment Panel and Systems.
(2) Remove (4) hex head screws to bl ower motor
cover (Fi g. 15).
(3) Di sconnect bl ower motor wi ri ng.
Fig. 11 A/C Pressure Transducer Removal
Fig. 12 Side View Of HVAC With Actuators
Fig. 14 Blend-Air Actuator
(4) Remove grommet for wi ri ng (Fi g. 16). Feed wi r-
i ng through bl ower housi ng (Fi g. 17).
(5) Remove mounti ng screws for bl ower motor (Fi g.
18).
(6) Al l ow the bl ower assembl y to drop down, and
remove assembl y from vehi cl e.
INSTALLATION
BLOWER MOTOR RESISTOR BLOCK
REMOVAL
(1) Open hood.
(2) Locate and remove the wi re connector from the
bl ower resi stor bl ock. Bl ock i s l ocated at the back of
the engi ne compartment on the passenger si de of the
vehi cl e under the wi per modul e (Fi g. 19).
NOTE: It is not necessary to remove the wiper
module to access the resistor block.
WARNING: THE RESISTOR BLOCK MAY BE HOT.
DO NOT ATTEMPT TO SERVICE THE RESISTOR
BLOCK IF THE SYSTEM HAS BEEN RUNNING
RECENTLY. LET THE SYSTEM COOL DOWN
BEFORE REPAIRS ARE INITIATED.
Fig. 16 Wiring Grommet
Fig. 17 Feeding Wiring Through Housing
Fig. 19 Resistor Block Removal
(3) Remove resi stor bl ock by i nserti ng a fl at bl ade
pry tool on the si de of the resi stor bl ock and pushi ng
i nward. Two gui de l i nes are shown on the ri ght hand
edge of the resi stor bl ock to hel p gui de the bl ade
posi ti on. Thi s wi l l rel ease the cl i ps on the si de of the
resi stor bl ock. Pul l resi stor bl ock out.
INSTALLATION
Make sure the TOP l etteri ng i s on the top of the
resi stor. The coi l s on the Resi stor Bl ock shoul d not be
contacti ng one another. Before i nstal l ati on, gentl y
separate the coi l s (wi th fi ngers onl y) i f one coi l i s
contacti ng another.
BLOWER MOTOR WHEEL
The bl ower motor wheel i s not servi ced separatel y.
I f the wheel needs to be repl aced i t i s servi ced as an
assembl y of the bl ower motor. For servi ce procedure
i nformati on, refer to Bl ower Motor Repl acement i n
thi s group.
COMPRESSOR (2. 5L TURBO DIESEL)
REMOVAL
WARNING: REFER TO REFRIGERANT SERVICE
PROCEDURES FOR INFORMATION REGARDING
PROPER RECOVERY OF THE REFRIGERANT
BEFORE ATTEMPTING TO REMOVE THE COM-
PRESSOR.
(2) Recl ai m refri gerant.
(4) Remove refri gerant l i nes from compressor and
cap al l l i nes (Fi g. 10).
(5) Remove fl ex dri ve bol ts from behi nd the power
steeri ng pump (Fi g. 20).
(6) Remove compressor mounti ng bol ts (Fi g. 20).
(7) pry compressor off of the dowel pi ns and
remove compressor.
INSTALLATION
(1) Transfer mounti ng spacer/bushi ngs onto the
new compressor.
(2) Li ft compressor i nto pl ace and start compressor
mounti ng bol ts. Do not ti ghten bol ts at thi s ti me. The
compressor may have to be moved sl i ghtl y to al i gn
the fl ex dri ve bol ts.
(3) Al i gn compressor cl utch wi th fl ex dri ve. Then
start both fl ex dri ve bol ts. Ti ghten the bol ts after
both fl ex dri ve bol ts have been i nstal l ed.
(4) Ti ghten compressor mounti ng bol ts.
(5) Lower vehi cl e and i nstal l refri gerant l i nes.
Al ways repl ace O-ri ngs and gaskets.
(6) Evacuate refri gerant system. Charge system
wi th the correct amount of R-134a refri gerant. The
refri gerant capaci ty i s .91 kg. 7 gm. (32 oz. 2.0
oz.).
CONDENSER ASSEMBLY
REMOVAL
(3) Remove (2) nuts attachi ng fi l ter-dri er to radi a-
tor modul e.
(5) Ti l t radi ator rearward.
(6) Remove upper di scharge l i ne at condenser (Fi g.
10).
(7) Through fasci a, remove l ower l i qui d l i ne from
fi l ter-dri er.
(8) Remove (2) l ower condenser mounti ng bol ts.
(9) Remove (2) upper mounti ng bol ts.
(10) Remove condenser from vehi cl e (Fi g. 22).
INSTALLATION
NOTE: Inspect Cooling Module for presence of
seals. Verify seals are available for re-installation.
kets, coat al l seal i ng surfaces wi th approved wax-free
refri gerant oi l . Then reverse the above procedures.
(2) Evacuate and charge system.
DISCHARGE LINE
REMOVAL
(2) Remove di scharge l i ne mounti ng nut at com-
pressor (Fi g. 10).
(3) Remove di scharge l i ne at the top fi tti ng on the
condenser (Fi g. 23).
INSTALLATION
Repl ace al l O-ri ngs.
(2) Evacuate and recharge A/C system.
nosti c and Cool down test.
Fig. 20 Compressor Components (2.5L Turbo Diesel)
EVAPORATOR PROBE
REMOVAL
(1) Remove the gl ove box. Refer to Group 8E,
I nstrument Panel and Systems.
(2) Di sconnect the evaporator probe connector (Fi g.
24).
(3) Usi ng a fl at bl ade pry tool , pry the evaporator
probe grommet from the HVAC housi ng (Fi g. 25).
(4) Remove evaporator probe from evaporator (Fi g.
26).
Fig. 21 Filter-Drier
Fig. 22 Condenser Removal
Fig. 23 Condenser Discharge Line
Fig. 24 Evaporator Probe Connector
Fig. 25 Evaporator Probe Grommet
INSTALLATION
Three hol es are provi ded i n evaporator for probe
l ocati on. When rei nstal l i ng probe, use a di fferent
hol e than ori gi nal one. I f a new evaporator i s
i nstal l ed, i nsert the probe i n the uppermost hol e pro-
vi ded.
EXPANSION VALVE
REMOVAL
(5) Di sconnect generator fi el d wi re connector.
(6) Push generator forward.
28).
(10) Careful l y pul l the refri gerant l i ne seal i ng
pl ate assembl y from expansi on val ve towards the
front of the vehi cl e. Use care not to scratch the
expansi on val ve seal i ng surfaces wi th pi l ot tubes.
(12) Remove two screws securi ng the expansi on
val ve to the evaporator seal i ng pl ate (Fi g. 28).
(13) Careful l y remove expansi on val ve (Fi g. 29).
INSTALLATION
(1) Ensure ol d O-ri ngs are removed. I nstal l new
O-ri ngs on the refri gerant l i nes and evaporator seal -
i ng pl ate.
Fig. 26 Evaporator Probe Fig. 27 A/C Refrigerant Line Plate
Fig. 28 Expansion Valve Stud and Mounting Screws
Fig. 29 Expansion Valve Removal
(2) Hand-start the stud i nto the expansi on val ve
and torque to 7 - 11 Nm (64 - 96 i n. l bs.).
(3) Careful l y i nstal l the expansi on val ve to the
seal i ng pl ate. I nstal l the two screws and ti ghten 8 to
14 Nm (70 to 130 i n. l bs.) torque.
(4) Careful l y i nstal l the refri gerant l i nes and seal -
i ng pl ate to the expansi on val ve. I nstal l the nut and
ti ghten 20 to 26 Nm (170 to 230 i n. l bs.) torque.
(5) I nstal l the ground wi re at dash panel .
(6) Pul l generator back i nto the proper posi ti on for
bracket mounti ng.
(7) I nstal l generator fi el d wi re connector.
(8) I nstal l the upper generator bracket.
(9) I nstal l accessory dri ve bel t.
(11) After expansi on val ve i s i nstal l ed, the system
i s charged, and l eaks have checked repeat the A/C
performance check.
FILTER-DRIER ASSEMBLY
REMOVAL
(3) Remove the (2) bol ts hol di ng fi l ter-dri er bracket
to radi ator fan modul e bracket.
(4) Remove the l ower l i qui d l i ne at condenser.
(5) Remove the upper radi ator crossmember.
(6) Pul l up on radi ator and sl i de fi l ter-dri er from
the mounti ng l ocati on.
INSTALLATION
(1) Before i nstal l ati on, repl ace both refri gerant
l i ne O-ri ngs. Then reverse the above procedures.
HEATER A/C UNIT HOUSING
REMOVAL
WARNING: IF EQUIPPED WITH AIR CONDITIONING,
THE REFRIGERATION SYSTEM MUST BE COM-
PLETELY EMPTY BEFORE PROCEEDING.
(1) Set parki ng brake.
Wi ndshi el d Wi pers and Washers.
(5) Drai n engi ne cool ant. Remove heater hoses at
the heater core, refer to Heater Hoses Removal and
I nstal l ati on procedures. Pl ug cool ant l i nes.
(6) Remove sucti on and l i qui d l i nes at the expan-
si on val ve (Fi g. 27).
(7) Remove the I nstrument Panel Assembl y. Refer
to Group 8E, I nstrument Panel and Systems.
(8) Remove heater ducts.
(9) Di sconnect the two upper mounts from the
upper rei nforcement and the l ower mount from the
tunnel .
(10) Remove the (3) nuts (i n the engi ne compart-
ment) securi ng the uni t to the dash panel (Fi g. 30).
(11) Di sconnect the HVAC housi ng wi ri ng harness.
(12) Pul l the enti re uni t rearward unti l the studs
on the uni t cl ear the dash panel . Drop the uni t down.
Pul l i t rearward to remove i t from vehi cl e.
INSTALLATION
(1) For i nstal l ati on of the assembl y, reverse the
above procedures. I nstal l new O-ri ngs on pl umbi ng
i nl ets
(2) Evacuate and recharge the A/C system.
(3) Perform HVAC control Cal i brati on Di agnosti c
and Cool down test.
HEATER CORE
REMOVAL
(1) Drai n cool ant system.
(2) Remove l eft si de l ower col umn cover.
(3) Remove steeri ng col umn assembl y. Refer to
Group 19, Steeri ng for servi ce procedure.
(4) Remove ABS modul e, bracket and wi ri ng (Fi g.
31).
(5) Remove I /P to body harness i nterconnect and
bracket (Fi g. 32).
(6) Remove l ower si l encer boot at base of steeri ng
shaft (Fi g. 33)
(7) Pi nch off heater l i nes under the hood.
Fig. 30 HVAC Bolt-Up
(8) Remove heater core cover. I nsert a smal l
amount of towel s under the heater core tubes.
Remove heater core pl ate and tubes (Fi g. 34).
(9) Depress heater core retai ni ng cl i ps (Fi g. 35).
(10) Pul l up on accel erator pedal and sl i de heater
core past (Fi g. 36).
(11) Depress brake pedal (Fi g. 37) and remove
heater core from HVAC housi ng.
Fig. 31 ABS MODULE
Fig. 32 Interconnect And Bracket
Fig. 33 Lower Silencer Boot
Fig. 34 Heater Core Plate And Tubes
Fig. 35 Depress Clips
Fig. 36 Accelerator Pedal
INSTALLATION
I nstal l screws to retai n heater core i n housi ng.
Repl ace heater core tube i nl et O-ri ngs. Ti ghten
heater core tube retai ni ng pl ate to 3 1 Nm (27
HEATER HOSES
REMOVAL
(1) Drai n engi ne cool i ng system. Refer to Group 7,
Engi ne Cool i ng.
(2) Loosen cl amps at each end of heater hose to be
removed (Fi g. 38) and (Fi g. 39).
CAUTION: When removing hoses from heater core
inlet or outlet nipples, do not use excessive force.
Heater core may become damaged and leak engine
coolant.
INSTALLATION
LIQUID LINE
REMOVAL
28).
(6) Remove l i qui d l i ne from expansi on val ve.
(8) Di sconnect wi re connector at pressure trans-
ducer.
(9) Remove l i qui d l i ne mounti ng cl i p at ri ght strut
tower.
(10) Usi ng access sl ot between radi ator crossmem-
ber and gri l l e, l oosen l i qui d l i ne mounti ng pl ate at
fi l ter-dri er. Remove l i qui d l i ne from fi l ter-dri er.
INSTALLATION
cl e.
Fig. 37 Brake Pedal
Fig. 38 Upper Heater Hose
Fig. 39 Lower Heater Hose
MODE DOOR ACTUATOR
REMOVAL
tems.
(3) Remove mode actuator connector (Fi g. 41).
(4) Remove mode door actuator (Fi g. 42).
INSTALLATION
SIDE WINDOW DEMISTER DUCTS
LEFT SIDE
The LEFT si de wi ndow demi ster duct i s a two
pi ece desi gn. The l eft si de has a l ong duct that
attaches to an i ntermedi ate duct and then to the di s-
tri buti on housi ng. The duct i s l ocated on top of the
i nstrument panel . To servi ce the duct, remove the I /P
cover and remove duct retai ners/fasteners. (Fi g. 43).
RIGHT SIDE
The demi ster duct on the ri ght si de i s a one pi ece
desi gn. I t i s one l ong duct that attaches to the di stri -
buti on housi ng. The duct i s l ocated on top of the
i nstrument panel and i t i s not servi ceabl e (Fi g. 44).
SUCTION LINE
REMOVAL
28).
(6) Remove sucti on l i ne from expansi on val ve.
Fig. 41 Mode Door Actuator Connector
Fig. 42 Mode Door Actuator
Fig. 43 Left Side Demister Duct
(7) Remove sucti on l i ne mounti ng nut at compres-
sor (Fi g. 10).
(8) Remove sucti on l i ne mounti ng bracket.
(9) Remove sucti on l i ne.
INSTALLATION
cl e.
RECIRC DOOR ACTUATOR
REMOVAL
(1) Pul l back on carpeti ng on the ri ght l ower fl oor.
(2) Remove Reci rc. door actuator connector.
(3) Remove (3) mounti ng screws for Reci rc. actua-
tor (Fi g. 45).
(4) Remove Reci rc. actuator.
(5) Di sengage actuator l i nkage at Reci rc. door.
(6) Remove actuator from vehi cl e.
INSTALLATION
HEATER A/C UNIT RECONDITION
Heater A/C Housi ng must be removed from vehi cl e
before performi ng thi s operati on. Refer to Heater A/C
Uni t Housi ngRemoval and I nstal l ati on.
DISASSEMBLYEVAPORATOR HOUSING
(1) Pl ace HVAC uni t assembl y on workbench.
(2) Remove di stri buti on housi ng mounti ng screws
(Fi g. 46).
(3) Remove bl ower motor cover (Fi g. 47).
Fig. 44 Right Side Demister Duct
Fig. 45 Recirculation Door Actuator
(4) Remove bl ower motor wi ri ng grommet and feed
wi ri ng through bl ower housi ng (Fi g. 48).
(5) Remove bl ower motor screws. Remove bl ower
motor from housi ng (Fi g. 49) and (Fi g. 50).
(6) Remove reci rcul ati on door cover (Fi g. 51).
(7) Remove Reci rc. door (Fi g. 52).
(8) Remove screws around the peri meter of the
upper HVAC housi ng (Fi g. 53).
Fig. 48 Blower Motor Grommet
Fig. 51 Recirculation Door Cover
Fig. 52 Recirc. Door
Fig. 53 HVAC Cover
CAUTION: Do not damage the insulation barrier
surrounding the evaporator.
(9) Careful l y pul l up on evaporator and remove
from housi ng (Fi g. 54).
(10) I f repl aci ng evaporator, drai n and measure
amount of oi l from ol d evaporator and add new oi l of
the same amount (ND8 PAG) to the new evaporator
before i nstal l i ng. Use SP 10 PAG oi l for 2.5L di esel
and 2.0L gasol i ne engi ne vehi cl es.
ASSEMBLYEVAPORATOR HOUSING
(1) For reassembl y of the evaporator housi ng,
reverse the above procedures.
DISASSEMBLYDISTRIBUTION HOUSING
(1) Pl ace di stri buti on housi ng on workbench (Fi g.
55).
(2) Remove heater core cover (Fi g. 56).
(3) Remove heater core tube pl ate (Fi g. 57) and
(Fi g. 58).
(4) Remove heater core tubes (Fi g. 59).
Fig. 54 Evaporator
Fig. 56 Heater Core Cover
Fig. 57 Heater Core Tube Plate
Fig. 58 Plate Removal
(5) Depress heater core retai ni ng cl i ps at housi ng.
When rei nstal l i ng core use screws to fasten the
heater core to the housi ng.
(6) Sl i de heater core out of the housi ng.
(7) Remove dri vers zone actuator from di stri buti on
(8) Remove passenger zone actuator from di stri bu-
ti on housi ng (Fi g. 61).
(9) Usi ng a l ong thi n fl at bl ade tool , i nsert tool
through bl end-ai r openi ng on top of di stri buti on
housi ng (Fi g. 62). Depress cl i p retai ni ng the dri vers
bl end-ai r door dri ve gear. Pul l out on gear and
remove from the housi ng (Fi g. 63).
(10) Remove mode door motor.
(11) Remove Panel door actuator gear (Fi g. 64).
(12) Remove defrost door actuator gear (Fi g. 65).
(13) Remove cam wheel (Fi g. 66).
Fig. 59 Heater Core Tube Removal
Fig. 60 Drivers Zone Actuator
Fig. 61 Passenger Zone Actuator
Fig. 63 Blend-Air Door Drive Gear
(14) Remove heat door actuator gear (Fi g. 67).
(15) Remove di stri buti on housi ng l ower cover
screws (Fi g. 68).
(16) Remove di stri buti on housi ng hal f screws (Fi g.
69).
(17) Remove di stri buti on housi ng front cover (Fi g.
70) and (Fi g. 71).
Fig. 64 Panel Door Gear
Fig. 65 Defrost Door Gear
Fig. 66 Cam Wheel
Fig. 67 Heat Door Gear
Fig. 69 Distribution Housing Half Screws
(18) Remove weather-stri p at fresh-ai r vent.
(19) Separate housi ng hal ves (Fi g. 72).
(20) Pul l up on separator pl ate and remove defrost
door (Fi g. 73).
(21) Remove upper hal f Panel door (Fi g. 74).
(22) Remove upper hal f of Fl oor door (Fi g. 75).
(23) Remove upper hal f of the bl end-ai r door (sl i de
off of shaft) (Fi g. 76).
Fig. 70 Front Cover
Fig. 71 View of Zone Control Doors
Fig. 72 Distribution Housing Halves
Fig. 73 Defrost Door
Fig. 74 Panel Door
Fig. 75 Floor Door
(24) Remove separator pl ate from di stri buti on
(25) Remove l ower hal f of the bl end-ai r door (Fi g.
78).
(26) Remove l ower hal f of the Panel door (Fi g. 79).
(27) Remove l ower hal f of the Fl oor door (Fi g. 80).
ASSEMBLYDISTRIBUTION HOUSING
For reassembl y of the di stri buti on housi ng, reverse
the above procedures.
To reassembl e the di stri buti on housi ng actuator
gears an assembl y procedure of the gears and cam i s
necessary.
ACTUATOR GEARS ALIGNMENT PROCEDURE
(1) I nstal l l ower FLOOR door actuator gear to
housi ng. Match master spl i ne of FLOOR door actua-
tor gear to master spl i ne on door.
(2) I nstal l cam wheel . Al i gn cam wheel track to
FLOOR door actuator gear.
(3) Al i gn cam wheel sl ot wi th the post on the di s-
tri buti on housi ng marked 1.
Fig. 76 Blend-Air Door
Fig. 77 Separator Plate
Fig. 78 Lower Blend-Air Door
Fig. 79 Lower Panel Door
Fig. 80 Lower Floor Door
(4) I nstal l PANEL door actuator gear. Al i gn master
spl i ne of PANEL door actuator gear to master spl i ne
on PANEL door. Posi ti on actuator gear wi thi n cam
wheel track.
(5) I nstal l DEFROST door actuator gear to hous-
i ng. Match master spl i ne of DEFROST door actuator
to master spl i ne on DEFROST door. Posi ti on actuator
gear wi thi n cam wheel track.
(6) Rei nstal l housi ng i n vehi cl e.
EMISSION CONTROL SYSTEMS
CONTENTS
page page
EVAPORATIVE EMISSION CONTROLS . . . . . . . . 13
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
ON-BOARD DIAGNOSTICS . . . . . . . . . . . . . . . . . . 1
INDEX
page page
GENERAL INFORMATION
SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . 1
CIRCUIT ACTUATION TEST MODE . . . . . . . . . . . 3
COMPONENT MONITORS . . . . . . . . . . . . . . . . . 10
DIAGNOSTIC TROUBLE CODES . . . . . . . . . . . . . 3
HIGH AND LOW LIMITS . . . . . . . . . . . . . . . . . . . 11
LOAD VALUE . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
MALFUNCTION INDICATOR LAMP (MIL) . . . . . . . 1
MONITORED SYSTEMS . . . . . . . . . . . . . . . . . . . . 8
NON-MONITORED CIRCUITS . . . . . . . . . . . . . . . 11
STATE DISPLAY TEST MODE . . . . . . . . . . . . . . . 2
TRIP DEFINITION . . . . . . . . . . . . . . . . . . . . . . . . 10
GENERAL INFORMATION
SYSTEM DESCRIPTION
many di fferent ci rcui ts i n the fuel i njecti on, i gni ti on,
emi ssi on and engi ne systems. I f the PCM senses a
probl em wi th a moni tored ci rcui t often enough to
i ndi cate an actual probl em, i t stores a Di agnosti c
Troubl e Code (DTC) i n the PCMs memory. I f the
code appl i es to a non-emi ssi ons rel ated component or
system, and the probl em i s repai red or ceases to
exi st, the PCM cancel s the code after 40 warmup
cycl es. Di agnosti c troubl e codes that affect vehi cl e
emi ssi ons i l l umi nate the Mal functi on I ndi cator Lamp
(MI L). Refer to Mal functi on I ndi cator Lamp i n thi s
secti on.
Certai n cri teri a must be met before the PCM
stores a DTC i n memory. The cri teri a may be a spe-
ci fi c range of engi ne RPM, engi ne temperature,
and/or i nput vol tage to the PCM.
The PCM mi ght not store a DTC for a moni tored
ci rcui t even though a mal functi on has occurred. Thi s
may happen because one of the DTC cri teri a for the
ci rcui t has not been met. For example, assume the
di agnosti c troubl e code cri teri a requi res the PCM to
moni tor the ci rcui t onl y when the engi ne operates
between 750 and 2000 RPM. Suppose the sensors
output ci rcui t shorts to ground when engi ne operates
above 2400 RPM (resul ti ng i n 0 vol t i nput to the
PCM). Because the condi ti on happens at an engi ne
speed above the maxi mum threshol d (2000 rpm), the
PCM wi l l not store a DTC.
There are several operati ng condi ti ons for whi ch
the PCM moni tors and sets DTCs. Refer to Moni -
tored Systems, Components, and Non-Moni tored Ci r-
cui ts i n thi s secti on.
NOTE: Various diagnostic procedures may actually
cause a diagnostic monitor to set a DTC. For
instance, pulling a spark plug wire to perform a
spark test may set the misfire code. When a repair
is completed and verified, use the DRB scan tool to
erase all DTCs and extinguish the MIL.
Techni ci ans can di spl ay stored DTCs by usi ng the
DRB scan tool . Refer to Di agnosti c Troubl e Codes i n
thi s secti on. For DTC i nformati on, refer to charts i n
thi s secti on.
MALFUNCTION INDICATOR LAMP (MIL)
As a functi onal test, the Mal functi on I ndi cator
Lamp (MI L) i l l umi nates at key-on before engi ne
NS EMISSION CONTROL SYSTEMS 25 - 1
cranki ng. Whenever the Powertrai n Control Modul e
(PCM) sets a Di agnosti c Troubl e Code (DTC) that
affects vehi cl e emi ssi ons, i t i l l umi nates the MI L. I f a
probl em i s detected, the PCM sends a message over
the CCD Bus to the i nstrument cl uster to i l l umi nate
the l amp. The PCM i l l umi nates the MI L onl y for
DTCs that affect vehi cl e emi ssi ons. The MI L stays
on conti nuousl y when the PCM has entered a
Li mp-I n mode or i denti fi ed a fai l ed emi ssi on compo-
nent or system. The MI L remai ns on unti l the DTC
i s erased. Refer to the Di agnosti c Troubl e Code
charts i n thi s group for emi ssi on rel ated codes.
Al so, the MI L ei ther fl ashes or i l l umi nates conti n-
uousl y when the PCM detects acti ve engi ne mi sfi re.
Refer to Mi sfi re Moni tori ng i n thi s secti on.
Addi ti onal l y, the PCM may reset (turn off) the MI L
when one of the fol l owi ng occur:
PCM does not detect the mal functi on for 3 con-
secuti ve tri ps (except mi sfi re and fuel system moni -
tors).
PCM does not detect a mal functi on whi l e per-
formi ng three successi ve engi ne mi sfi re or fuel sys-
tem tests. The PCM performs these tests whi l e the
engi ne i s operati ng wi thi n 375 RPM of and wi thi n
10 % of the l oad of the operati ng condi ti on at whi ch
the mal functi on was fi rst detected.
STATE DISPLAY TEST MODE
The swi tch i nputs to the Powertrai n Control Mod-
ul e (PCM) have two recogni zed states; HI GH and
LOW. For thi s reason, the PCM cannot recogni ze the
di fference between a sel ected swi tch posi ti on versus
an open ci rcui t, a short ci rcui t, or a defecti ve swi tch.
I f the State Di spl ay screen shows the change from
HI GH to LOW or LOW to HI GH, assume the enti re
swi tch ci rcui t to the PCM functi ons properl y. From
the state di spl ay screen, access ei ther State Di spl ay
I nputs and Outputs or State Di spl ay Sensors.
STATE DISPLAY INPUTS AND OUTPUTS
Connect the DRB scan tool to the data l i nk connec-
tor and access the State Di spl ay screen. Then access
I nputs and Outputs. The fol l owi ng l i st contai ns the
PCM system functi ons accessi bl e through the I nputs
and Outputs screen.
Park/Neutral Swi tch
Speed Control Resume
Brake Swi tch
Speed Control On/Off
Speed Control Set
S/C Vent Sol enoi d
Actual S/C Vent Sol .
S/C Vacuum Sol enoi d
Actual S/C Vacuum Sol .
S/C Cancel
S/C Last Cutout
S/C Worki ng Status
S/C Deni ed Status
A/C Cl utch Rel ay
Actual A/C Cl utch Rel ay
EGR Sol enoi d
Actual EGR Sol .
Automati c Shutdown Rel ay
Actual Automati c Shutdown Rel ay
Automati c Shutdown Rel ay Sense
Radi ator Fan Control Modul e
Actual Radi ator Fan Control Modul e
Duty Cycl e EVAP Purge Sol enoi d
Actual EVAP Purge Sol .
Torque Converter Cl utch Sol enoi d
Power Steeri ng Swi tch
Cl osed Loop State
Current CMP Edge
Current CKP State
Current Sync State
Fuel Pump Rel ay
Actual Fuel Pump Rel ay
I gni ti on Sense (A21)
Mal functi on Lamp
Li mp-i n Reason
STATE DISPLAY SENSORS
Connect the DRB scan tool to the vehi cl e and
access the State Di spl ay screen. Then access Sensor
Di spl ay. The fol l owi ng l i st contai ns the PCM system
functi ons accessi bl e through the Sensor Di spl ay
screen.
Battery Temperature
Engi ne Cool ant Temperature
Engi ne Cool ant Temp Sensor
Throttl e Posi ti on Vol ts
Mi ni mum Throttl e
Knock Sensor Vol ts
Battery Vol tage
MAP Sensor Readi ng
I dl e Ai r Control Motor Posi ti on
Fig. 1 Data Link (Diagnostic) Connector
25 - 2 EMISSION CONTROL SYSTEMS NS
Adapti ve Fuel Factor
Barometri c Pressure
Engi ne Speed
Modul e Spark Advance
Speed Control Target
I ntake Ai r Temp Degrees
I ntake Ai r Temp Vol ts
Chargi ng System Goal
Theft Al arm Status
Map Sensor Vol tage
Vehi cl e Speed
Throttl e Openi ng (percentage)
TPS Cal cul ated
Cam Ti mi ng Posi ti on
Target I dl e
Ti me From Start To Run
Run Ti me At Stal l
I njector Pul se-wi dth
Upstream O2S Vol ts
Downstream O2S Vol ts
Cl osed Loop Ti mer
Short Term Adapti ve
Current Adapti ve Cel l
Adapti ve Memory Cel l 0
Purge Free I dl e Cel l
Purge Free Cel l 2 (corresponds to memory cel l 2)
Purge Free Cel l 3 (corresponds to memory cel l 5)
Target I AC Steps
Retard Cyl i nder (1)
CIRCUIT ACTUATION TEST MODE
The Ci rcui t Actuati on Test Mode checks for proper
operati on of output ci rcui ts or devi ces the Powertrai n
Control Modul e (PCM) may not i nternal l y recogni ze.
The PCM attempts to acti vate these outputs and
al l ow an observer to veri fy proper operati on. Most of
the tests provi de an audi bl e or vi sual i ndi cati on of
devi ce operati on (cl i ck of rel ay contacts, fuel spray,
etc.). Except for i ntermi ttent condi ti ons, i f a devi ce
functi ons properl y duri ng testi ng, assume the devi ce,
i ts associ ated wi ri ng, and dri ver ci rcui t work cor-
rectl y.
A Di agnosti c Troubl e Code (DTC) i ndi cates the
PCM has recogni zed an abnormal condi ti on i n the
system.
The preferred and most accurate method of retri ev-
i ng a DTC i s by usi ng the DRB scan tool . The scan
tool suppl i es detai l ed di agnosti c i nformati on whi ch
can be used to more accuratel y di agnose causes for a
DTC.
Remember that DTCs are the results of a sys-
tem or circuit failure, but do not directly iden-
tify the failed component or components.
NOTE: For a list of DTCs, refer to the charts in this
section.
BULB CHECK
Each ti me the i gni ti on key i s turned to the ON
posi ti on, the mal functi on i ndi cator (check engi ne)
l amp on the i nstrument panel shoul d i l l umi nate for
approxi matel y 2 seconds then go out. Thi s i s done for
a bul b check.
OBTAINING DTCS USING DRB SCAN TOOL
(1) Connect the DRB scan tool to the data l i nk
(2) Turn the i gni ti on swi tch on and access the
Read Faul t screen.
(3) Record al l the DTCs and freeze frame i nfor-
mati on shown on the DRB scan tool .
(4) To erase DTCs, use the Erase Troubl e Code
data screen on the DRB scan tool . Do not erase any
DTCs until problems have been investigated
and repairs have been performed.
DIAGNOSTIC TROUBLE CODE DESCRIPTIONS
HEX
CODE
GENERIC
SCAN
TOOL
CODE
DRB SCAN TOOL
DISPLAY
DESCRIPTION OF DIAGNOSTIC
TROUBLE CODE
01 P0340 No Cam Signal at PCM No camshaft signal detected during engine
cranking.
02 P0601 Internal Controller Failure PCM Internal fault condition detected.
05 Charging System Voltage Too Low Battery voltage sense input below target charging
during engine operation. Also, no significant
change detected in battery voltage during active
test of generator output circuit.
06 Charging System Voltage Too High Battery voltage sense input above target charging
voltage during engine operation.
0A* Auto Shutdown Relay Control
Circuit
An open or shorted condition detected in the auto
shutdown relay circuit.
0B Generator Field Not Switching
Properly
An open or shorted condition detected in the
generator field control circuit.
0C P0743 Torque Converter Clutch Soleniod/
Trans Relay Circuits
An open or shorted condition detected in the
torque converter part throttle unlock solenoid
control circuit (3 speed auto RH trans. only).
0E P1491 Rad Fan Control Relay Circuit An open or shorted condition detected in the low
speed radiator fan relay control circuit.
0F* Speed Control Solenoid Circuits An open or shorted condition detected in the
Speed Control vacuum or vent solenoid circuits.
10* A/C Clutch Relay Circuit An open or shorted condition detected in the A/C
clutch relay circuit.
11 P0403 EGR Solenoid Circuit An open or shorted condition detected in the EGR
transducer solenoid circuit.
12 P0443 EVAP Purge Solenoid Circuit An open or shorted condition detected in the duty
cycle purge solenoid circuit.
13 P0203 Injector #3 Control Circuit Injector #3 output driver does not respond properly
to the control signal.
19 P0505 Idle Air Control Motor Circuits A shorted or open condition detected in one or
more of the idle air control motor circuits.
1A P0122 Throttle Position Sensor Voltage
Low
Throttle position sensor input below the minimum
acceptable voltage
1B P0123 Throttle Position Sensor Voltage
High
Throttle position sensor input above the maximum
acceptable voltage.
1E P0117 ECT Sensor Voltage Too Low Engine coolant temperature sensor input below
minimum acceptable voltage.
1F P0118 ECT Sensor Voltage Too High Engine coolant temperature sensor input above
maximum acceptable voltage.
HEX
CODE
GENERIC
SCAN
TOOL
CODE
DRB SCAN TOOL
DISPLAY
TROUBLE CODE
20 P0134 Right Rear (or just) Upstream O2S
Stays at Center
Neither rich or lean condition detected from the
oxygen sensor.
21* Engine Is Cold Too Long Engine did not reach operating temperature within
acceptable limits.
23 P0500 No Vehicle Speed Sensor Signal No vehicle speed sensor signal detected during
road load conditions.
24 P0107 MAP Sensor Voltage Too Low MAP sensor input below minimum acceptable
voltage.
25 P0108 MAP Sensor Voltage Too High MAP sensor input above maximum acceptable
voltage.
27 P1297 No Change in MAP From Start to
Run
No difference recognized between the engine MAP
reading and the barometric (atmospheric) pressure
reading from start-up.
28* No Crank Reference Signal at PCM No crank reference signal detected during engine
cranking.
29 P0353 Ignition Coil #3 Primary Circuit Peak primary circuit current not achieved with
maximum dwell time.
2A P0352 Ignition Coil #2 Primary Circuit Peak primary circuit current not achieved with
maximum dwell time.
2B P0351 Ignition Coil #1 Primary Circuit Peak primary circuit current not achieved with
maximum dwell time.
2C* No ASD Relay Output Voltage at
PCM
An Open condition Detected In The ASD Relay
Output Circuit.
2E P0401 EGR System Failure Required change in air/fuel ratio not detected
during diagnostic test.
30* P1697 PCM Failure SRI Miles Not Stored Unsuccessful attempt to update EMR mileage in
the PCM EEPROM.
31 P1698 PCM Failure EEPROM Write
Denied
Unsuccessful attempt to write to an EEPROM
location by the PCM.
39 P0112 Intake Air Temp Sensor Voltage
Low
Intake air temperature sensor input below the
maximum acceptable voltage.
3A P0113 Intake Air Temp Sensor Voltage
High
Intake air temperature sensor input above the
minimum acceptable voltage.
3C P0106 Barometric Pressure Out Of Range MAP sensor has a baro reading below an
acceptable value.
3D P0204 Injector #4 Control Circuit Injector #4 output driver does not respond properly
3E P0132 Right Rear (or just) Upstream O2S
Shorted to Voltage
Oxygen sensor input voltage maintained above the
normal operating range.
44 P0600 PCM Failure SPI Communications PCM Internal fault condition detected.
HEX
CODE
GENERIC
SCAN
TOOL
CODE
DRB SCAN TOOL
DISPLAY
TROUBLE CODE
52* SPD CTRL PWR RLY; or S/C 12v
Driver CKT
Malfunction detected with power feed to speed
control servo solenoids.
5A A/C Pressure Sensor Volts Too
High
Sensor input voltage is above 4.9 volts.
5B A/C Pressure Sensor Volts Too Low Sensor input voltage is below .098 volts.
60 P1698 No CCD Messages From TCM No messages received from Transmission Control
Module.
61 No CCD Message From Body
Control Module
No messages received from Body Control Module.
65* Fuel Pump Relay Control Circuit An open or shorted condition detected in the fuel
pump relay control circuit.
66 P0133 Right Bank Upstream O2S Slow
Response
Oxygen sensor response slower than minimum
required switching frequency.
67 P0135 Right Rear (or just) Upstream O2S
Heater Failure
Upstream oxygen sensor heating element circuit
malfunction.
69 P0141 Right Rear (or just) Downstream
O2S Heater Failure
Oxygen sensor heating element circuit malfunction.
6A P0300 Multiple Cylinder Mis-fire Misfire detected in multiple cylinders.
6B P0301 Cylinder #1 Mis-fire Misfire detected in cylinder #1.
6C P0302 Cylinder #2 Mis-fire Misfire detected in cylinder #2.
6D P0303 Cylinder #3 Mis-fire Misfire detected in cylinder #3.
6E P0304 Cylinder #4 Mis-fire Misfire detected in cylinder #4.
70 P0420 Right Rear (or just) Catalyst
Efficency Failure
Catalyst efficiency below required level.
71* P0441 Evap Purge Flow Monitor Failure Insufficient or excessive vapor flow detected during
evaporative emission system operation.
72 P1899 P/N Switch Stuck in Park or in Gear Incorrect input state detected for the Park/Neutral
switch, auto. trans. only.
76 P0172 Right Rear (or just) Fuel System
Rich
A rich air/fuel mixture has been indicated by an
abnormally lean correction factor.
77 P0171 Right Rear (or just) Fuel System
Lean
A lean air/fuel mixture has been indicated by an
abnormally rich correction factor.
7E P0138 Right Rear (or just) Downstream
O2S Shorted to Voltage
Oxygen sensor input voltage maintained above the
normal operating range.
80 P0128 Closed Loop Temp Not Reached Engine does not reach 20F within 5 minutes with
a vehicle speed signal.
81 P0140 Right Rear (or just) Downstream
O2S Stays at Center
Neither reich or lean condition detected from the
downstream oxygen sensor.
84 P0121 TPS Voltage Does Not Agree With
MAP
TPS signal does not correlate to MAP sensor
89 P0700 EATX Controller DTC Present An automatic transmission input DTC has been set
in the transmission controller. Refer to Group 21.
8A P1294 Target Idle Not Reached Actual idle speed does not equal target idle speed.
HEX
CODE
GENERIC
SCAN
TOOL
CODE
DRB SCAN TOOL
DISPLAY
TROUBLE CODE
92 P1496 5 Volt Supply Output Too Low 5 volt output from regulator does not meet
minimum requirement.
94* P0740 Torq Conv Clu, No RPM Drop At
Lockup
Relationship between engine speed and vehicle
speed indicates no torque converter clutch
engagement (auto. trans. only).
95* Fuel Level Sending Unit Volts Too
Low
Open circuit between PCM and fuel gauge sending
unit.
96* Fuel Level Sending Unit Volts Too
High
Circuit shorted to voltage between PCM and fuel
gauge sending unit.
97* Fuel Level Unit No Change Over
Miles
No movement of fuel level sender detected.
98 P0703 Brake Switch Stuck Pressed or
Released
No release of brake switch seen after too many
accelerations.
99 P1493 Ambient/Batt Temp Sen VoltsToo
Low
Battery temperature sensor input voltage below an
acceptable range.
9A P1492 Ambient/Batt Temp Sensor VoltsToo
High
Battery temperature sensor input voltage above an
acceptable range.
9B P0131 Right Rear (or just) Upstream O2S
Shorted to Ground
O2 sensor voltage too low, tested after cold start.
9C P0137 Right Rear (or just) Downstream
O2S Shorted to Ground
O2 sensor voltage too low, tested after cold start.
9D P1391 Intermittent Loss of CMP or CKP Intermittent loss of either camshaft or crankshaft
position sensor
A0 P0442 Evap Leak Monitor Small Leak
Detected
A small leak has been detected by the leak
detection monitor.
A1 P0455 Evap Leak Monitor Large Leak
Detected
The leak detection monitor is unable to pressurize
Evap system, indicating a large leak.
AE P0305 Cylinder #5 Mis-fire Misfire detected in cylinder #5.
AF P0306 Cylinder #6 Mis-fire Misfire detected in cylinder #6.
B7 P1495 Leak Detect ion Pump Solenoid
Circuit
Leak detection pump solenoid circuit fault (open or
short).
B8 P1494 Leak Detect Pump Sw or
Mechanical Fault
Leak detection pump switch does not respond to
input.
BA P1398 Mis-fire Adaptive Numerator at Limit CKP sensor target windows have too much
variation
BB P1486 Evap Leak Monitor Pinched Hose
Found
Plug or pinch detected between purge solenoid
and fuel tank.
BE P1290 CNG System Pressure Too High Compressed natural gas pressure sensor reading
above acceptable voltage.
C0 P0133 Cat Mon Slow O2 Upstream Oxygen sensor response slower than minimum
required switching frequency during catalyst
monitor.
* Check Engi ne Lamp (MI L) wi l l not i l l umi nate i f thi s Di agnosti c Troubl e Code was recorded.
MONITORED SYSTEMS
There are new el ectroni c ci rcui t moni tors that
check fuel , emi ssi on, engi ne and i gni ti on perfor-
mance. These moni tors use i nformati on from vari ous
sensor ci rcui ts to i ndi cate the overal l operati on of the
fuel , engi ne, i gni ti on and emi ssi on systems and thus
the emi ssi ons performance of the vehi cl e.
The fuel , engi ne, i gni ti on and emi ssi on systems
moni tors do not i ndi cate a speci fi c component prob-
l em. They do i ndi cate that there i s an i mpl i ed prob-
l em wi thi n one of the systems and that a speci fi c
probl em must be di agnosed.
I f any of these moni tors detect a probl em affecti ng
vehi cl e emi ssi ons, the Mal functi on I ndi cator (Check
Engi ne) Lamp wi l l be i l l umi nated. These moni tors
generate Di agnosti c Troubl e Codes that can be di s-
pl ayed wi th the check engi ne l amp or a scan tool .
The fol l owi ng i s a l i st of the system moni tors:
EGR Moni tor
Mi sfi re Moni tor
Fuel System Moni tor
Oxygen Sensor Moni tor
Oxygen Sensor Heater Moni tor
Catal yst Moni tor
Evaporati ve System Leak Detecti on Moni tor
Fol l owi ng i s a descri pti on of each system moni tor,
and i ts DTC.
Refer to the appropriate Powertrain Diagnos-
tics Procedures manual for diagnostic proce-
dures.
HEX 66, and 7AOXYGEN SENSOR (O2S)
MONITOR
Effecti ve control of exhaust emi ssi ons i s achi eved
by an oxygen feedback system. The most i mportant
el ement of the feedback system i s the O2S. The O2S
i s l ocated i n the exhaust path. Once i t reaches oper-
ati ng temperature 300 to 350C (572 to 662F), the
sensor generates a vol tage that i s i nversel y propor-
ti onal to the amount of oxygen i n the exhaust. The
i nformati on obtai ned by the sensor i s used to cal cu-
l ate the fuel i njector pul se wi dth. Thi s mai ntai ns a
14.7 to 1 ai r fuel (A/F) rati o. At thi s mi xture rati o,
the catal yst works best to remove hydrocarbons (HC),
carbon monoxi de (CO) and ni trous oxi de (NOx) from
the exhaust.
The O2S i s al so the mai n sensi ng el ement for the
EGR, Catal yst and Fuel Moni tors.
The O2S may fai l i n any or al l of the fol l owi ng
manners:
Sl ow response rate
Reduced output vol tage
Dynami c shi ft
Shorted or open ci rcui ts
Response rate i s the ti me requi red for the sensor to
swi tch from l ean to ri ch once i t i s exposed to a ri cher
than opti mum A/F mi xture or vi ce versa. As the sen-
sor starts mal functi oni ng, i t coul d take l onger to
detect the changes i n the oxygen content of the
exhaust gas.
The output vol tage of the O2S ranges from 0 to 1
vol t. A good sensor can easi l y generate any output
vol tage i n thi s range as i t i s exposed to di fferent con-
centrati ons of oxygen. To detect a shi ft i n the A/F
mi xture (l ean or ri ch), the output vol tage has to
change beyond a threshol d val ue. A mal functi oni ng
sensor coul d have di ffi cul ty changi ng beyond the
threshol d val ue.
HEX 67, 69, 7C, and 7DOXYGEN SENSOR
HEATER MONITOR
I f there i s an oxygen sensor (O2S) DTC as wel l as
a O2S heater DTC, the O2S faul t MUST be repai red
fi rst. After the O2S faul t i s repai red, veri fy that the
heater ci rcui t i s operati ng correctl y.
Effecti ve control of exhaust emi ssi ons i s achi eved
by an oxygen feedback system. The most i mportant
el ement of the feedback system i s the O2S. The O2S
i s l ocated i n the exhaust path. Once i t reaches oper-
ati ng temperature 300 to 350C (572 to 662F), the
sensor generates a vol tage that i s i nversel y propor-
ti onal to the amount of oxygen i n the exhaust. The
i nformati on obtai ned by the sensor i s used to cal cu-
l ate the fuel i njector pul se wi dth. Thi s mai ntai ns a
14.7 to 1 Ai r Fuel (A/F) rati o. At thi s mi xture rati o,
the catal yst works best to remove hydrocarbons (HC),
carbon monoxi de (CO) and ni trogen oxi de (NOx) from
the exhaust.
The vol tage readi ngs taken from the O2S are very
temperature sensi ti ve. The readi ngs are not accurate
bel ow 300C. Heati ng of the O2S i s done to al l ow the
engi ne control l er to shi ft to cl osed l oop control as
soon as possi bl e. The heati ng el ement used to heat
the O2S must be tested to ensure that i t i s heati ng
the sensor properl y.
The O2S ci rcui t i s moni tored for a drop i n vol tage.
The sensor output i s used to test the heater by i so-
l ati ng the effect of the heater el ement on the O2S
output vol tage from the other effects.
HEX 2EEGR MONITOR
The Powertrai n Control Modul e (PCM) performs
an on-board di agnosti c check of the EGR system.
The EGR system consi sts of two mai n components:
a vacuum sol enoi d and a vacuum operated val ve wi th
a back pressure transducer. The EGR moni tor i s used
to test whether the EGR system i s operati ng wi thi n
speci fi cati ons. The di agnosti c check acti vates onl y
duri ng sel ected engi ne/dri vi ng condi ti ons. When the
condi ti ons are met, the EGR i s turned off (sol enoi d
energi zed) and the O2S compensati on control i s mon-
i tored. Turni ng off the EGR shi fts the ai r fuel (A/F)
rati o i n the l ean di recti on. The O2S data shoul d i ndi -
cate an i ncrease i n the O2 concentrati on i n the com-
busti on chamber when the exhaust gases are no
l onger reci rcul ated. Whi l e thi s test does not di rectl y
measure the operati on of the EGR system, i t can be
i nferred from the shi ft i n the O2S data whether the
EGR system i s operati ng correctl y. Because the O2S
i s bei ng used, the O2S test must pass i ts test before
the EGR test.
HEX 6A,6B, 6C, 6D, 6E, AE, and AFMISFIRE
MONITOR
Excessi ve engi ne mi sfi re resul ts i n i ncreased cata-
l yst temperature and causes an i ncrease i n HC emi s-
si ons. Severe mi sfi res coul d cause catal yst damage.
To prevent catal yti c convertor damage, the PCM
moni tors engi ne mi sfi re.
for mi sfi re duri ng most engi ne operati ng condi ti ons
(posi ti ve torque) by l ooki ng at changes i n the crank-
shaft speed. I f a mi sfi re occurs the speed of the
crankshaft wi l l vary more than normal .
HEX 76, 77, 78, and 79FUEL SYSTEM
MONITOR
To compl y wi th cl ean ai r regul ati ons, vehi cl es are
equi pped wi th catal yti c converters. These converters
reduce the emi ssi on of hydrocarbons, oxi des of ni tro-
gen and carbon monoxi de. The catal yst works best
when the ai r fuel (A/F) rati o i s at or near the opti -
mum of 14.7 to 1.
The PCM i s programmed to mai ntai n the opti mum
ai r/fuel rati o of 14.7 to 1. Thi s i s done by maki ng
short term correcti ons i n the fuel i njector pul se wi dth
based on the O2S output. The programmed memory
acts as a sel f cal i brati on tool that the engi ne control -
l er uses to compensate for vari ati ons i n engi ne spec-
i fi cati ons, sensor tol erances and engi ne fati gue over
the l i fe span of the engi ne. By moni tori ng the actual
ai r-fuel rati o wi th the O2S (short term) and mul ti pl y-
i ng that wi th the program l ong-term (adapti ve) mem-
ory and compari ng that to the l i mi t, i t can be
determi ned whether i t wi l l pass an emi ssi ons test. I f
a mal functi on occurs such that the PCM cannot
mai ntai n the opti mum A/F rati o, then the MI L wi l l
be i l l umi nated.
HEX 70, and B4CATALYST MONITOR
To compl y wi th cl ean ai r regul ati ons, vehi cl es are
equi pped wi th catal yti c converters. These converters
reduce the emi ssi on of hydrocarbons, oxi des of ni tro-
gen and carbon monoxi de.
Normal vehi cl e mi l es or engi ne mi sfi re can cause a
catal yst to decay. A mel tdown of the cerami c core can
cause a reducti on of the exhaust passage. Thi s can
i ncrease vehi cl e emi ssi ons and deteri orate engi ne
performance, dri veabi l i ty and fuel economy.
The catal yst moni tor uses dual oxygen sensors
(O2Ss) to moni tor the effi ci ency of the converter. The
dual O2Ss strategy i s based on the fact that as a cat-
al yst deteri orates, i ts oxygen storage capaci ty and i ts
effi ci ency are both reduced. By moni tori ng the oxy-
gen storage capaci ty of a catal yst, i ts effi ci ency can
be i ndi rectl y cal cul ated. The upstream O2S i s used to
detect the amount of oxygen i n the exhaust gas
before the gas enters the catal yti c converter. The
PCM cal cul ates the A/F mi xture from the output of
the O2S. A l ow vol tage i ndi cates hi gh oxygen content
(l ean mi xture). A hi gh vol tage i ndi cates a l ow content
of oxygen (ri ch mi xture).
When the upstream O2S detects a l ean condi ti on,
there i s an abundance of oxygen i n the exhaust gas.
A functi oni ng converter woul d store thi s oxygen so i t
can use i t for the oxi dati on of HC and CO. As the
converter absorbs the oxygen, there wi l l be a l ack of
oxygen downstream of the converter. The output of
the downstraem O2S wi l l i ndi cate l i mi ted acti vi ty i n
thi s condi ti on.
As the converter l oses the abi l i ty to store oxygen,
the condi ti on can be detected from the behavi or of
the downstream O2S. When the effi ci ency drops, no
chemi cal reacti on takes pl ace. Thi s means the con-
centrati on of oxygen wi l l be the same downstream as
upstream. The output vol tage of the downstream
O2S copi es the vol tage of the upstream sensor. The
onl y di fference i s a ti me l ag (seen by the PCM)
between the swi tchi ng of the O2Ss.
To moni tor the system, the number of l ean-to-ri ch
swi tches of upstream and downstream O2Ss i s
counted. The rati o of downstream swi tches to
upstream swi tches i s used to determi ne whether the
catal yst i s operati ng properl y. An effecti ve catal yst
wi l l have fewer downstream swi tches than i t has
upstream swi tches i .e., a rati o cl oser to zero. For a
total l y i neffecti ve catal yst, thi s rati o wi l l be one-to-
one, i ndi cati ng that no oxi dati on occurs i n the devi ce.
The system must be moni tored so that when cata-
l yst effi ci ency deteri orates and exhaust emi ssi ons
i ncrease to over the l egal l i mi t, the MI L (check
engi ne l amp) wi l l be i l l umi nated.
HEX A0, A1, B7, and B8LEAK DETECTION
PUMP MONITOR
The l eak detecti on assembl y i ncorporates two pri -
mary functi ons: i t must detect a l eak i n the evapora-
ti ve system and seal the evaporati ve system so the
l eak detecti on test can be run.
The pri mary components wi thi n the assembl y are:
A three port sol enoi d that acti vates both of the func-
ti ons l i sted above; a pump whi ch contai ns a swi tch,
two check val ves and a spri ng/di aphragm, a cani ster
vent val ve (CVV) seal whi ch contai ns a spri ng l oaded
vent seal val ve.
I mmedi atel y after a col d start, between predeter-
mi ned temperature threshol ds l i mi ts, the three port
sol enoi d i s bri efl y energi zed. Thi s i ni ti al i zes the
pump by drawi ng ai r i nto the pump cavi ty and al so
cl oses the vent seal . Duri ng non test condi ti ons the
vent seal i s hel d open by the pump di aphragm
assembl y whi ch pushes i t open at the ful l travel posi -
ti on. The vent seal wi l l remai n cl osed whi l e the
pump i s cycl i ng due to the reed swi tch tri ggeri ng of
the three port sol enoi d that prevents the di aphragm
assembl y from reachi ng ful l travel . After the bri ef
i ni ti al i zati on peri od, the sol enoi d i s de-energi zed
al l owi ng atmospheri c pressure to enter the pump
cavi ty, thus permi tti ng the spri ng to dri ve the di a-
phragm whi ch forces ai r out of the pump cavi ty and
i nto the vent system. When the sol enoi d i s energi zed
and de energi zed, the cycl e i s repeated creati ng fl ow
i n typi cal di aphragm pump fashi on. The pump i s con-
trol l ed i n 2 modes:
Pump Mode: The pump i s cycl ed at a fi xed rate to
achi eve a rapi d pressure bui l d i n order to shorten the
overal l test l ength.
Test Mode: The sol enoi d i s energi zed wi th a fi xed
durati on pul se. Subsequent fi xed pul ses occur when
the di aphragm reaches the Swi tch cl osure poi nt.
The spri ng i n the pump i s set so that the system
wi l l achi eve an equal i zed pressure of about 7.5 H20.
The cycl e rate of pump strokes i s qui te rapi d as the
system begi ns to pump up to thi s pressure. As the
pressure i ncreases, the cycl e rate starts to drop off. I f
there i s no l eak i n the system, the pump woul d even-
tual l y stop pumpi ng at the equal i zed pressure. I f
there i s a l eak, i t wi l l conti nue to pump at a rate rep-
resentati ve of the fl ow characteri sti c of the si ze of the
l eak. From thi s i nformati on we can determi ne i f the
l eak i s l arger than the requi red detecti on l i mi t (cur-
rentl y set at .020 ori fi ce by CARB). I f a l eak i s
reveal ed duri ng the l eak test porti on of the test, the
test i s termi nated at the end of the test mode and no
further system checks wi l l be performed.
After passi ng the l eak detecti on phase of the test,
system pressure i s mai ntai ned by turni ng on the
LDPs sol enoi d unti l the purge system i s acti vated.
Purge acti vati on i n effect creates a l eak. The cycl e
rate i s agai n i nterrogated and when i t i ncreases due
to the fl ow through the purge system, the l eak check
porti on of the di agnosti c i s compl ete.
The cani ster vent val ve wi l l unseal the system
after compl eti on of the test sequence as the pump
di aphragm assembl y moves to the ful l travel posi ti on.
Evaporati ve system functi onal i ty wi l l be veri fi ed by
usi ng the stri cter evap purge fl ow moni tor. At an
appropri ate warm i dl e the LDP wi l l be energi zed to
seal the cani ster vent. The purge fl ow wi l l be cl ocked
up from some smal l val ue i n an attempt to see a
shi ft i n the 02 control system. I f fuel vapor, i ndi cated
by a shi ft i n the 02 control , i s present the test i s
passed. I f not, i t i s assumed that the purge system i s
not functi oni ng i n some respect. The LDP i s agai n
turned off and the test i s ended.
TRIP DEFINITION
A Tri p means vehi cl e operati on (fol l owi ng an
engi ne-off peri od) of durati on and dri vi ng mode such
that al l components and systems are moni tored at
l east once by the di agnosti c system. The moni tors
must successful l y pass before the PCM can veri fy
that a previ ousl y mal functi oni ng component i s meet-
i ng the normal operati ng condi ti ons of that compo-
nent. For mi sfi re or fuel system mal functi on, the
MI L may be exti ngui shed i f the faul t does not recur
when moni tored duri ng three subsequent sequenti al
dri vi ng cycl es i n whi ch condi ti ons are si mi l ar to
those under whi ch the mal functi on was fi rst deter-
mi ned.
Anyti me the MI L i s i l l umi nated, a DTC i s stored.
The DTC can sel f erase onl y when the MI L has been
exti ngui shed. Once the MI L i s exti ngui shed, the
PCM must pass the di agnosti c test for the most
recent DTC for 40 warm-up cycl es (80 warm-up
cycl es for the Fuel System Moni tor and the Mi sfi re
Moni tor). A warm-up cycl e can best be descri bed by
the fol l owi ng:
The engi ne must be runni ng
A ri se of 40F i n engi ne temperature must occur
from the ti me when the engi ne was started
Engi ne cool ant temperature must reach at l east
160F
A dri vi ng cycl e that consi sts of engi ne start up
and engi ne shut off.
Once the above condi ti ons occur, the PCM i s con-
si dered to have passed a warm-up cycl e. Due to the
condi ti ons requi red to exti ngui sh the MI L and erase
the DTC, i t i s most i mportant that after a repai r has
been made, al l DTCs be erased and the repai r veri -
fi ed.
COMPONENT MONITORS
There are several components that wi l l affect vehi -
cl e emi ssi ons i f they mal functi on. I f one of these com-
ponents mal functi ons the Mal functi on I ndi cator
Lamp (Check Engi ne) wi l l i l l umi nate.
Some of the component moni tors are checki ng for
proper operati on of the part. El ectri cal l y operated
components now have i nput (rati onal i ty) and output
(functi onal i ty) checks. Previ ousl y, a component l i ke
the Throttl e Posi ti on sensor (TPS) was checked by
the PCM for an open or shorted ci rcui t. I f one of
these condi ti ons occurred, a DTC was set. Now there
i s a check to ensure that the component i s worki ng.
Thi s i s done by watchi ng for a TPS i ndi cati on of a
greater or l esser throttl e openi ng than MAP and
engi ne rpm i ndi cate. I n the case of the TPS, i f engi ne
vacuum i s hi gh and engi ne rpm i s 1600 or greater
and the TPS i ndi cates a l arge throttl e openi ng, a
DTC wi l l be set. The same appl i es to l ow vacuum
and 1600 rpm.
Any component that has an associ ated l i mp i n wi l l
set a faul t after 1 tri p wi th the mal functi on present.
Refer to the Di agnosti c Troubl e Codes Descri pti on
Charts i n thi s secti on and the appropri ate Power-
trai n Di agnosti c Procedure Manual for di agnosti c
procedures.
NON-MONITORED CIRCUITS
The PCM does not moni tor al l ci rcui ts, systems
and condi ti ons that coul d have mal functi ons causi ng
dri veabi l i ty probl ems. However, probl ems wi th these
systems may cause the PCM to store di agnosti c trou-
bl e codes for other systems or components. For exam-
pl e, a fuel pressure probl em wi l l not regi ster a faul t
di rectl y, but coul d cause a ri ch/l ean condi ti on or mi s-
fi re. Thi s coul d cause the PCM to store an oxygen
sensor or mi sfi re di agnosti c troubl e code.
The major non-moni tored ci rcui ts are l i sted bel ow
al ong wi th exampl es of fai l ures modes that do not
di rectl y cause the PCM to set a DTC, but for a sys-
tem that i s moni tored.
FUEL PRESSURE
The fuel pressure regul ator control s fuel system
pressure. The PCM cannot detect a cl ogged fuel
pump i nl et fi l ter, cl ogged i n-l i ne fuel fi l ter, or a
pi nched fuel suppl y or return l i ne. However, these
coul d resul t i n a ri ch or l ean condi ti on causi ng the
PCM to store an oxygen sensor or fuel system di ag-
nosti c troubl e code.
SECONDARY IGNITION CIRCUIT
The PCM cannot detect an i noperati ve i gni ti on coi l ,
foul ed or worn spark pl ugs, i gni ti on cross fi ri ng, or
open spark pl ug cabl es.
CYLINDER COMPRESSION
The PCM cannot detect uneven, l ow, or hi gh engi ne
cyl i nder compressi on.
EXHAUST SYSTEM
The PCM cannot detect a pl ugged, restri cted or
l eaki ng exhaust system. I t may set a EGR or Fuel
system faul t or O2S.
FUEL INJ ECTOR MECHANICAL
MALFUNCTIONS
The PCM cannot determi ne i f a fuel i njector i s
cl ogged, the needl e i s sti cki ng or i f the wrong i njector
i s i nstal l ed. However, these coul d resul t i n a ri ch or
l ean condi ti on causi ng the PCM to store a di agnosti c
troubl e code for ei ther mi sfi re, an oxygen sensor, or
the fuel system.
EXCESSIVE OIL CONSUMPTION
Al though the PCM moni tors engi ne exhaust oxygen
content when the system i s i n cl osed l oop, i t cannot
determi ne excessi ve oi l consumpti on.
THROTTLE BODY AIR FLOW
The PCM cannot detect a cl ogged or restri cted ai r
cl eaner i nl et or fi l ter el ement.
VACUUM ASSIST
The PCM cannot detect l eaks or restri cti ons i n the
vacuum ci rcui ts of vacuum assi sted engi ne control
system devi ces. However, these coul d cause the PCM
to store a MAP sensor di agnosti c troubl e code and
cause a hi gh i dl e condi ti on.
PCM SYSTEM GROUND
The PCM cannot determi ne a poor system ground.
However, one or more di agnosti c troubl e codes may
be generated as a resul t of thi s condi ti on. The mod-
ul e shoul d be mounted to the body at al l ti mes, al so
duri ng di agnosti c.
PCM CONNECTOR ENGAGEMENT
The PCM may not be abl e to determi ne spread or
damaged connector pi ns. However, i t mi ght store
di agnosti c troubl e codes as a resul t of spread connec-
tor pi ns.
HIGH AND LOW LIMITS
The PCM compares i nput si gnal vol tages from each
i nput devi ce wi th establ i shed hi gh and l ow l i mi ts for
the devi ce. I f the i nput vol tage i s not wi thi n l i mi ts
and other cri teri a are met, the PCM stores a di agnos-
ti c troubl e code i n memory. Other di agnosti c troubl e
code cri teri a mi ght i ncl ude engi ne RPM l i mi ts or
i nput vol tages from other sensors or swi tches that
must be present before veri fyi ng a di agnosti c troubl e
code condi ti on.
LOAD VALUE
ENGINE IDLE/NEUTRAL 2500 RPM/NEUTRAL
2.4 Auto. Trans. 4.4% of Maximun Load 11.7% of Maximun Load
3.0L 4.2% of Maximun Load 11.5% of Maximun Load
3.3L 5% of Maximun Load 13.4% of Maximun Load
3.8L 4.7% of Maximun Load 13.3% of Maximun Load
EVAPORATIVE EMISSION CONTROLS
INDEX
page page
CRANKCASE VENT FILTER . . . . . . . . . . . . . . . . 16
EVAPORATION CONTROL SYSTEM . . . . . . . . . 13
EVAPORATIVE (EVAP) CANISTER . . . . . . . . . . . 13
LEAK DETECTION PUMP . . . . . . . . . . . . . . . . . 14
POSITIVE CRANKCASE VENTILATION (PCV)
SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
PRESSURE-VACUUM FILLER CAP . . . . . . . . . . 14
PROPORTIONAL PURGE SOLENOID . . . . . . . . . 13
ROLLOVER VALVE . . . . . . . . . . . . . . . . . . . . . . . 13
VEHICLE EMISSION CONTROL INFORMATION
LABEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
LEAK DETECTION PUMP . . . . . . . . . . . . . . . . . 16
PCV VALVE TEST . . . . . . . . . . . . . . . . . . . . . . . 16
LEAK DETECTION PUMP REPLACEMENT . . . . 16
ROLLOVER VALVES . . . . . . . . . . . . . . . . . . . . . 17
EVAPORATION CONTROL SYSTEM
The evaporati on control system prevents the emi s-
si on of fuel tank vapors i nto the atmosphere. When
fuel evaporates i n the fuel tank, the vapors pass
through vent hoses or tubes to a charcoal fi l l ed evap-
orati ve cani ster. The cani ster temporari l y hol ds the
vapors. The Powertrai n Control Modul e (PCM) al l ows
i ntake mani fol d vacuum to draw vapors i nto the com-
busti on chambers duri ng certai n operati ng condi -
ti ons.
Al l engi nes use a duty cycl e purge system. The
PCM control s vapor fl ow by operati ng the duty cycl e
EVAP purge sol enoi d. Refer to Duty Cycl e EVAP
Purge Sol enoi d i n thi s secti on.
NOTE: The evaporative system uses specially man-
ufactured hoses. If they need replacement, only use
fuel resistant hose.
ROLLOVER VALVE
Al l vehi cl es have a rol l over val ve. The val ve al so
prevents fuel fl ow through the fuel tank vent val ve
hoses shoul d the vehi cl e rol l over. Al l vehi cl es pass a
360 rol l over.
The charcoal fi l l ed evaporati ve cani ster stores the
vapors. The rol l over val ve i s not a servi ceabl e i tem.
EVAPORATIVE (EVAP) CANISTER
Al l vehi cl es use a seal ed, mai ntenance free, evapo-
rati ve (charcoal ) cani ster. The cani ster i s attached to
the frame under the dri vers seat (Fi g. 1).
Fuel tank vapor vents i nto the cani ster. The cani s-
ter temporari l y hol ds the fuel vapors unti l i ntake
mani fol d vacuum draws them i nto the combusti on
chamber. The cani ster proporti onal purge sol enoi d
al l ows the cani ster to be purged at predetermi ned
i nterval s and engi ne condi ti ons.
PROPORTIONAL PURGE SOLENOID
Al l vehi cl es use a Proporti onal purge sol enoi d. The
sol enoi d regul ates the rate of vapor fl ow from the
EVAP cani ster to the throttl e body. The PCM oper-
ates the sol enoi d.
noi d. When de-energi zed, no vapors are purged. The
PCM de-energi zes the sol enoi d duri ng open l oop oper-
ati on.
The proporti onal purge sol enoi d operates at a fre-
quency of 200hz and i s control l ed by an engi ne con-
trol l er ci rcui t that senses the current bei ng appl i ed
to the proporti onal purge sol enoi d and then adjusts
that current to achi eve the desi red purge fl ow. The
proporti onal purge sol enoi d control s the purge rate of
fuel vapors from the vapor cani ster and fuel tank to
the engi ne i ntake mani fol d.
CAUTION: Remove the fuel filler cap to relieve fuel
tank pressure. The cap must be removed prior to
disconnecting any fuel system component or ser-
vicing the fuel tank.
A pressure-vacuum rel i ef cap seal s the fuel tank
(Fi g. 3). Ti ghteni ng the cap on the fuel fi l l er tube
forms a seal between them. The rel i ef val ves i n the
cap are a safety feature. They prevent possi bl e exces-
si ve pressure or vacuum i n the tank. Excessi ve fuel
tank pressure coul d be caused by a mal functi on i n
the system or damage to the vent l i nes.
The seal between the cap and fi l l er tube breaks
when the cap i s removed and rel i eves fuel tank pres-
sure.
I f the fi l l er cap needs repl acement, onl y use the
correct part.
LEAK DETECTION PUMP
The l eak detecti on pump i s a devi ce used to detect
a l eak i n the evaporati ve system.
The pump contai ns a 3 port sol enoi d, a pump that
contai ns a swi tch, a spri ng l oaded cani ster vent val ve
seal , 2 check val ves and a spri ng/di aphragm.
I mmedi atel y after a col d start, when the engi ne
temperature i s between 40F and 86F, the 3 port
sol enoi d i s bri efl y energi zed. Thi s i ni ti al i zes the
pump by drawi ng ai r i nto the pump cavi ty and al so
cl oses the vent seal . Duri ng non-test test condi ti ons,
the vent seal i s hel d open by the pump di aphragm
assembl y whi ch pushes i t open at the ful l travel posi -
ti on. The vent seal wi l l remai n cl osed whi l e the
pump i s cycl i ng. Thi s i s due to the operati on of the 3
port sol enoi d whi ch prevents the di aphragm assem-
bl y from reachi ng ful l travel . After the bri ef i ni ti al -
i zati on peri od, the sol enoi d i s de-energi zed, al l owi ng
atmospheri c pressure to enter the pump cavi ty. Thi s
permi ts the spri ng to dri ve the di aphragm whi ch
forces ai r out of the pump cavi ty and i nto the vent
system. When the sol enoi d i s energi zed and de-ener-
gi zed, the cycl e i s repeated creati ng fl ow i n typi cal
di aphragm pump fashi on. The pump i s control l ed i n
2 modes:
PUMP MODE: The pump i s cycl ed at a fi xed rate
to achi eve a rapi d pressure bui l d i n order to shorten
the overal l test ti me.
TEST MODE: The sol enoi d i s energi zed wi th a
fi xed durati on pul se. Subsequent fi xed pul ses occur
when the di aphragm reaches the swi tch cl osure
poi nt.
The spri ng i n the pump i s set so that the system
wi l l achi eve an equal i zed pressure of about 7.5 i nches
of water.
When the pump starts, the cycl e rate i s qui te hi gh.
As the system becomes pressuri zed, pump rate drops.
I f there i s no l eak, the pump wi l l qui t. I f there i s a
l eak, the test i s termi nated at the end of the test
mode.
I f there i s no l eak, the purge moni tor i s run. I f the
cycl e rate i ncreases due to the fl ow through the
purge system, the test i s passed and the di agnosti c i s
compl ete.
The cani ster vent val ve wi l l unseal the system
after compl eti on of the test sequence as the pump
di aphragm assembl y moves to the ful l travel posi ti on.
Fig. 3 Pressure Vacuum Filler Cap
POSITIVE CRANKCASE VENTILATION (PCV)
SYSTEMS
I ntake mani fol d vacuum removes crankcase vapors
and pi ston bl ow-by from the engi ne. The vapors pass
through the PCV val ve i nto the i ntake mani fol d
where they become part of the cal i brated ai r-fuel
mi xture. They are burned and expel l ed wi th the
exhaust gases. The ai r cl eaner suppl i es make up ai r
when the engi ne does not have enough vapor or
bl ow-by gases. I n thi s system, fresh fi l tered ai r
enters the crankcase (Fi g. 4), (Fi g. 5) and (Fi g. 6).
PCV VALVE
The PCV val ve contai ns a spri ng l oaded pl unger.
The pl unger meters the amount of crankcase vapors
routed i nto the combusti on chamber based on i ntake
mani fol d vacuum.
When the engi ne i s not operati ng or duri ng an
engi ne backfi re, the spri ng forces the pl unger back
agai nst the seat. Thi s prevents vapors from fl owi ng
through the val ve (Fi g. 7).
When the engi ne i s at i dl e or crui si ng, hi gh mani -
fol d vacuum i s present. At these ti mes mani fol d vac-
uum i s abl e to compl etel y compress the spri ng and
pul l the pl unger to the top of the val ve (Fi g. 8). I n
thi s posi ti on there i s mi ni mal vapor fl ow through the
val ve.
Duri ng peri ods of moderate i ntake mani fol d vac-
uum the pl unger i s onl y pul l ed part way back from
Fig. 5 PCV Valve 3.0L Engine
Fig. 6 PCV Valve and Fresh Air Hose 3.3/3.8L
Engines
Fig. 7 Engine Off or Engine BackfireNo Vapor
Flow
Fig. 8 High Intake Manifold VacuumMinimal Vapor
Flow
the i nl et. Thi s resul ts i n maxi mum vapor fl ow
through the val ve (Fi g. 9).
CRANKCASE VENT FILTER
Al l engi nes use fi l tered ai r to vent the crankcase.
The fi l tered ai r i s drawn through the resonator
assembl y l ocated between the ai r cl eaner and throttl e
body.
VEHICLE EMISSION CONTROL INFORMATION
LABEL
Al l model s have a Vehi cl e Emi ssi on Control I nfor-
mati on (VECI ) Label . Chrysl er permanentl y attaches
the l abel i n the engi ne compartment. I t cannot be
removed wi thout defaci ng i nformati on and destroyi ng
the l abel .
The l abel contai ns the vehi cl es emi ssi on speci fi ca-
ti ons and vacuum hose routi ngs. Al l hoses must be
connected and routed accordi ng to the l abel .
LEAK DETECTION PUMP
Refer to the appropri ate Powertrai n Di agnosti c
Procedures Manual for testi ng procedures.
PCV VALVE TEST
BLOCK WHEELS BEFORE PERFORMING ANY TEST
OR ADJUSTMENT WITH THE ENGINE OPERATING.
Wi th the engi ne i dl i ng, remove the PCV val ve from
i ts attachi ng poi nt. I f the val ve i s operati ng properl y,
a hi ssi ng noi se wi l l be heard and a strong vacuum
fel t when pl aci ng a fi nger over the val ve i nl et (Fi g.
10). Wi th the engi ne off, shake the val ve. The val ve
shoul d rattl e when shaken. Repl ace the val ve i f i t
does not operate properl y. Do not attempt to clean
the PCV valve.
LEAK DETECTION PUMP REPLACEMENT
REMOVAL
The Leak Detecti on Pump (LDP) i s l ocated under
the dri vers si de i n the cast cradl e under the steeri ng
gear (Fi g. 11).
(1) Rai se and support vehi cl e on a hoi st.
Fig. 9 Moderate Intake Manifold VacuumMaximum
Vapor Flow
Fig. 10 PCV Test Typical
Fig. 11 Leak Detection Pump
(2) Push l ocki ng tab on connector to unl ock (Fi g.
12).
(3) Push down on connector l atch and pul l connec-
tor from pump.
(4) Remove hoses.
(5) Remove bol ts hol di ng LDP and bracket to cra-
dl e.
(6) Remove bracket from LDP.
INSTALLATION
(1) I nstal l LDP to bracket.
(2) I nstal l LDP and bracket to cradl e. Torque bol ts
to 9.5-14 Nm (85-125 i n. l bs.). Before installing
hoses to LDP, make sure they are not cracked
or split. If a hose leaks, it will cause the Check
Engine Lamp to illuminate.
(3) I nstal l hoses to LDP.
(4) Pl ug el ectri cal connector i nto LDP.
(5) Push connector l ocki ng tab i nto pl ace.
(6) Usi ng DRB scan tool , veri fy proper operati on of
LDP.
ROLLOVER VALVES
Al l vehi cl es have 2 rol l over val ves on top of the
fuel tank. The val ves prevent fuel fl ow through the
fuel tank vent val ve hoses shoul d the vehi cl e rol l over.
The rol l over val ves on the fuel tank are not ser-
vi ceabl e.
Fig. 12 Leak Detection Pump Connector Lock
EXHAUST GAS RECIRCULATION (EGR) SYSTEM
INDEX
page page
EGR GAS FLOW TEST . . . . . . . . . . . . . . . . . . . 20
EGR SYSTEM ON-BOARD DIAGNOSTICS . . . . . 19
EGR SYSTEM TEST . . . . . . . . . . . . . . . . . . . . . 19
EGR VALVE CONTROL (TRANSDUCER) TEST . 21
EGR VALVE LEAKAGE TEST . . . . . . . . . . . . . . . 20
EGR TUBE SERVICE3.0L ENGINES . . . . . . . . 22
EGR TUBE SERVICE3.3/3.8L ENGINES . . . . . 22
EGR VALVE SERVICE3.0L ENGINES . . . . . . . 21
EGR VALVE SERVICE3.3/3.8L ENGINES . . . . 22
SPECIAL TOOLS
EMISSION CONTROL SYSTEM . . . . . . . . . . . . . 23
GENERAL INFORMATION
Refer to Moni tored Systems - EGR Moni tor i n thi s
group for more i nformati on.
The 3.0, 3.3, and 3.8L engi nes use Exhaust Gas
Reci rcul ati on (EGR) systems (Fi g. 1) and (Fi g. 2).
The EGR system reduces oxi des of ni trogen (NOx) i n
engi ne exhaust and hel ps prevent spark knock. The
system al l ows a predetermi ned amount of hot
exhaust gas to reci rcul ate and di l ute the i ncomi ng
ai r/fuel mi xture. The di l uted ai r/fuel mi xture reduces
peak fl ame temperature duri ng combusti on.
The EGR system consi sts of:
EGR tube (connects a passage i n the i ntake
mani fol d to the exhaust mani fol d)
EGR val ve
El ectroni c EGR Transducer
Connecti ng hoses
The El ectroni c EGR Transducer contai ns an el ec-
tri cal l y operated sol enoi d and a back-pressure trans-
ducer (Fi g. 3). The PCM operates the sol enoi d. The
PCM determi nes when to energi ze the sol enoi d.
Exhaust system back-pressure control s the trans-
ducer.
When the PCM energi zes the sol enoi d, vacuum
does not reach the transducer. Vacuum fl ows to the
transducer when the PCM de-energi zes the sol enoi d.
When exhaust system back-pressure becomes hi gh
enough, i t ful l y cl oses a bl eed val ve i n the trans-
ducer. When the PCM de-energi zes the sol enoi d and
back-pressure cl oses the transducer bl eed val ve, vac-
uum fl ows through the transducer to operate the
EGR val ve.
De-energi zi ng the sol enoi d, but not ful l y cl osi ng the
transducer bl eed hol e (because of l ow back-pressure),
vari es the strength of vacuum appl i ed to the EGR
val ve. Varyi ng the strength of the vacuum changes
Fig. 1 EGR Mounting3.0L Engine
Fig. 2 EGR Mounting3.3/3.8L Engines
the amount of EGR suppl i ed to the engi ne. Thi s pro-
vi des the correct amount of exhaust gas reci rcul ati on
for di fferent operati ng condi ti ons.
Thi s system does not al l ow EGR at i dl e. The EGR
systems can operate at al l cool ant temperatures
above 60F as l ong as the battery ambi ent tempera-
ture i s above 7F.
EGR SYSTEM ON-BOARD DIAGNOSTICS
The PCM performs an on-board di agnosti c check of
the EGR system. The di agnosti c system uses the
el ectroni c EGR transducer for the system tests.
The di agnosti c check acti vates onl y duri ng sel ected
engi ne/dri vi ng condi ti ons. When the condi ti ons are
met, the PCM energi zes the transducer sol enoi d to
di sabl e the EGR. The PCM checks for a change i n
the heated oxygen sensor si gnal . I f the ai r-fuel mi x-
ture goes l ean, the PCM wi l l attempt to enri chen the
mi xture. The PCM regi sters a Di agnosti c Troubl e
Code (DTC) i f the EGR system i s not operati ng cor-
rectl y. After regi steri ng a DTC, the PCM turns on the
mal functi on i ndi cator (Check Engi ne) l amp after 2
consecuti ve tri ps. There are 2 types of fai l ures sensed
by the PCM. The fi rst i s a short or open i n the el ec-
tri cal sol enoi d ci rcui t. The second i s a mechani cal
fai l ure or l oss of vacuum. The Mal functi on I ndi cator
Lamp (MI L) i ndi cates the need for servi ce.
I f a probl em i s i ndi cated by the MI L and a DTC for
the EGR system i s set, check for proper operati on of
the EGR system. Use the System Test, EGR Gas
Fl ow Test. I f the EGR system tests properl y, check
the system usi ng the DRB scan tool . Refer to
On-Board Di agnosi s secti ons i n thi s Group. Al so,
refer to the DRB scan tool and the appropri ate Pow-
ertrai n Di agnosti cs Procedure manual .
EGR SYSTEM TEST
BLOCK WHEELS BEFORE TESTING THE EGR SYS-
TEM.
(1) Check the condi ti on of al l EGR system hoses
and tubes for l eaks, cracks, ki nks and hardeni ng of
rubber hoses. Repai r and correct these condi ti ons
before performi ng any tests.
(2) Be sure the hoses at both the EGR val ve and
EGR val ve control are connected to the proper fi t-
ti ngs (Fi g. 4).
(3) Be sure the el ectri cal connector i s fi rml y con-
nected at the val ve control .
(4) To check EGR system operati on, connect the
DRB scan tool to the 16way data l i nk connector.
The data l i nk connector i s l ocated on the l ower edge
of the i nstrument panel near the steeri ng col umn.
Refer to the appropri ate Powertrai n Di agnosti c Pro-
cedures servi ce manual for operati on of the DRB
scan tool when di agnosi ng the EGR system.
(5) After checki ng the system wi th the DRB scan
tool , proceed to the fol l owi ng EGR Val ve Leakage and
EGR Val ve Control Tests and repai r as necessary.
Fig. 3 Electric EGR Transducer Assembly
Fig. 4 EGR Value and EGR Value Typical
EGR GAS FLOW TEST
Use the fol l owi ng test procedure to determi ne i f
exhaust gas i s fl owi ng through the EGR val ve. I t can
al so be used to determi ne i f the EGR tube i s pl ugged,
or the system passages i n the i ntake or exhaust man-
i fol ds are pl ugged.
Thi s i s not to be used as a compl ete test of the
EGR system.
The engi ne must be started, runni ng and warmed
to operati ng temperature for thi s test.
(1) Al l engi nes are equi pped wi th two fi tti ngs
l ocated on the EGR val ve (Fi g. 5). The upper fi tti ng
(l ocated on the vacuum motor) suppl i es engi ne vac-
uum to a di aphragm wi thi n the EGR val ve for val ve
operati on. The l ower fi tti ng (l ocated on the base of
the EGR val ve) i s used to suppl y exhaust back-pres-
sure to the EGR val ve control .
(2) Di sconnect the rubber hose at the vacuum
motor fi tti ng (Fi g. 5) on the top of the EGR val ve
vacuum motor.
(3) Connect a hand-hel d vacuum pump to thi s fi t-
ti ng.
(5) Sl owl y appl y 5 i nches of vacuum to the fi tti ng
on the EGR val ve motor.
(6) Whi l e appl yi ng vacuum, a mi ni mum of 3 i nches
of vacuum, and wi th the engi ne runni ng at i dl e
speed, the i dl e speed shoul d drop or the engi ne may
even stal l , i f the vacuum i s appl i ed qui ckl y. Thi s i s
i ndi cati ng that exhaust gas i s fl owi ng through the
EGR tube between the i ntake and exhaust mani fol ds.
(7) I f the engi ne speed di d not change, the EGR
val ve may be defecti ve, or EGR tube may be pl ugged
wi th carbon, or the passages i n the i ntake and
exhaust mani fol ds may be pl ugged wi th carbon.
(a) Remove EGR val ve from engi ne. Refer to
EGR Val ve Removal i n thi s group.
(b) Appl y vacuum to the vacuum motor fi tti ng
and observe the stem on the EGR val ve. I f the
stem i s movi ng, i t can be assumed that the EGR
val ve i s functi oni ng correctl y. The probl em i s i n
ei ther a pl ugged EGR tube or pl ugged passages at
the i ntake or exhaust mani fol ds, refer to step (c). I f
the stem wi l l not move, repl ace the EGR val ve.
Note: The EGR val ve, val ve control and attachi ng
hoses are servi ced as one uni t. Refer to EGR Val ve
Removal /I nstal l ati on i n thi s group.
(c) Remove the EGR tube between the i ntake
and exhaust mani fol ds. Check and cl ean the EGR
tube and i ts rel ated openi ngs on the mani fol ds.
Refer to EGR Tube i n thi s group for procedures.
(8) Do not attempt to cl ean the EGR val ve. I f the
val ve shows evi dence of heavy carbon bui l d-up near
the base, repl ace i t.
EGR VALVE LEAKAGE TEST
EGR system.
I f the engi ne wi l l not i dl e, di es out on i dl e, or i dl e
i s rough or sl ow, the poppet val ve (Fi g. 4) at the base
of the EGR val ve may be l eaki ng i n the cl osed posi -
ti on.
(1) The engi ne shoul d be off for the fol l owi ng test.
(2) Di sconnect the rubber hose from the fi tti ng
(Fi g. 4) at the top (vacuum motor) si de of the EGR
val ve.
(a) Connect a hand-hel d vacuum pump to thi s
fi tti ng.
(b) Appl y 15 i nches of vacuum to the pump.
(c) Observe the gauge readi ng on the pump.
(d) I f vacuum fal l s off, the di aphragm i n the
EGR val ve has ruptured.
(e) Repl ace the EGR val ve. Note: The EGR
val ve, val ve control and attachi ng hoses are ser-
vi ced as one assembl y. Refer to EGR Val ve Remov-
al /I nstal l ati on i n thi s group.
(f) Proceed to the next step.
(3) A smal l metal fi tti ng (back-pressure fi tti ng) i s
l ocated at the base of the EGR val ve (Fi g. 4). A rub-
ber back-pressure hose connects i t to the back-pres-
sure fi tti ng on the EGR val ve control . Di sconnect thi s
rubber hose at the EGR val ve fi tti ng.
(4) Remove the ai r cl eaner housi ng from the throt-
tl e body.
(5) Usi ng compressed ai r, and usi ng an ai r nozzl e
wi th a rubber ti p, appl y approxi matel y 50 psi of reg-
Fig. 5 Typical EGR Valve
ul ated shop ai r to the metal back- pressure fi tti ng on
the EGR val ve.
(6) By hand, open the throttl e to the wi de open
posi ti on. Ai r SHOULD NOT BE HEARD emi tti ng
from the i ntake mani fol d whi l e appl yi ng ai r pressure
at the back-pressure fi tti ng.
(7) I f ai r CAN BE HEARD emi tti ng from the
i ntake mani fol d, the poppet val ve (Fi g. 4) i s l eaki ng
at the bottom of the EGR val ve. Repl ace the EGR
val ve. Note: The EGR val ve, val ve control and
attachi ng hoses are servi ced as one assembl y. Refer
to EGR Val ve Removal /I nstal l ati on i n thi s group. Do
not attempt cl ean the ol d EGR val ve.
EGR VALVE CONTROL (TRANSDUCER) TEST
TESTING ELECTRICAL SOLENOID PORTION
OF VALVE
EGR system.
El ectri cal operati on of the val ve shoul d be checked
wi th the DRB scan tool . Refer to the appropri ate
Powertrai n Di agnosti c Procedures servi ce manual for
operati on of the DRB scan tool . Repl ace sol enoi d i f
necessary, uni t servi ced onl y as an assembl y.
TESTING VACUUM TRANSDUCER PORTION
OF VALVE
The fi rst part of thi s test wi l l determi ne i f the
transducer di aphragm at the back-pressure si de of
the val ve has ruptured or i s l eaki ng. The second part
of the test wi l l determi ne i f engi ne vacuum (ful l -man-
i fol d) i s fl owi ng from the i nl et to the outl et si de of
the val ve. Thi s i s not to be used as a compl ete test of
the EGR system.
(1) Di sconnect the rubber back-pressure hose from
the fi tti ng at the bottom of EGR val ve (Fi g. 4).
(2) Connect a hand-hel d vacuum pump to thi s fi t-
ti ng.
(3) Appl y 10 i nches of vacuum to thi s fi tti ng.
(4) I f vacuum fal l s off, the val ve di aphragm i s
l eaki ng.
(5) Repl ace the EGR val ve assembl y. Proceed to
next step for further testi ng.
(6) Remove the rubber hose at the vacuum inlet
fi tti ng (Fi g. 4) on the EGR val ve.
(7) Connect a vacuum gauge to thi s di sconnected
hose.
(8) Start the engi ne and bri ng to operati ng tem-
perature. Hol d engi ne speed at approxi matel y 1500
rpm.
(9) Check for steady engi ne vacuum (ful l -mani fol d)
at thi s hose.
(10) I f engi ne vacuum (ful l -mani fol d) i s not
present, check vacuum l i ne to engi ne and repai r as
necessary before proceedi ng to next step.
(11) Reconnect the rubber hose to the vacuum
inlet fi tti ng (Fi g. 4) on the EGR val ve.
(12) Di sconnect the rubber hose at the vacuum
outlet fi tti ng (Fi g. 4) on the EGR val ve.
(13) Connect a vacuum gauge to thi s fi tti ng.
(14) Di sconnect the el ectri cal connector (Fi g. 4) at
the val ve control . Thi s wi l l si mul ate an open ci rcui t
(no ground from the PCM) at the val ve.
(15) Start the engi ne and bri ng to operati ng tem-
perature.
(16) Hol d the engi ne speed to approxi matel y 2000
rpm whi l e checki ng for engi ne vacuum (ful l -mani fol d)
at thi s fi tti ng. To allow full manifold vacuum to
flow through the valve, exhaust back-pressure
must be present at valve. It must be high
enough to hold the bleed valve in the trans-
ducer portion of the valve closed. Have a hel per
momentari l y (a second or two) hol d a rag over the
tai l pi pe openi ng to bui l d some exhaust back-pressure
whi l e observi ng the vacuum gauge. Heavy gl oves
shoul d be worn. Do not cover the tailpipe open-
ing for an extended period of time as damage to
components or overheating may result.
(17) As temporary back-pressure i s bui l t, ful l man-
i fol d vacuum shoul d be observed at the vacuum out-
l et fi tti ng. Wi thout back-pressure, and engi ne at
approxi matel y 2000 rpm, the gauge readi ng wi l l be
l ow. Thi s l ow readi ng i s normal . At i dl e speed, the
gauge readi ng wi l l be errati c. Thi s i s al so normal .
(18) I f ful l mani fol d vacuum i s not present at the
outl et fi tti ng, but was present at the i nl et fi tti ng,
repl ace the val ve. Note: The EGR val ve, val ve control
and attachi ng hoses are servi ced as one assembl y.
Refer to EGR Val ve Removal /I nstal l ati on i n thi s
group.
EGR VALVE SERVICE3. 0L ENGINES
The EGR val ve and El ectri cal EGR Transducer are
servi ced as an assembl y.
REMOVAL
(1) Di sconnect the el ectri c and vacuum connectors
from the el ectri c EGR transducer (Fi g. 6).
(2) Remove EGR val ve mounti ng bol ts.
(3) Cl ean al l gasket surfaces and di scard ol d gas-
kets. Check for any si gns of l eakage or cracked sur-
faces. Repai r or repl ace as necessary.
INSTALLATION
(1) I nstal l EGR val ve and new gasket on i ntake
mani fol d. Ti ghten mounti ng bol ts to 22 Nm (200 i n.
l bs.) torque.
(2) Connect the el ectri cal and vacuum connectors
to the el ectri c EGR transducer.
EGR VALVE SERVICE3. 3/3. 8L ENGINES
The EGR val ve and El ectri cal EGR Transducer are
servi ced as an assembl y.
REMOVAL
(1) Di sconnect vacuum tube from el ectri c EGR
transducer. I nspect vacuum tube for damage (Fi g. 7).
(2) Remove el ectri cal connector from sol enoi d.
(3) Remove EGR val ve bol ts from i ntake mani fol d.
(4) Open EGR transducer cl i p and remove el ectri c
EGR transducer.
(5) Remove EGR val ve from i ntake mani fol d.
(6) Cl ean gasket surface and di scard ol d gasket.
Check for any si gns of l eakage or cracked surfaces.
Repai r or repl ace as necessary.
INSTALLATION
(1) Assembl e EGR val ve wi th new gasket onto the
i ntake mani fol d.
(2) I nstal l mounti ng bol ts. Ti ghten bol ts to 22 Nm
(3) I nstal l el ectri c EGR transducer i n cl i p wi th ori -
entati on tab i n sl ot and snap cl osed.
(4) Reconnect vacuum hose and el ectri cal connec-
tor to el ectri cal EGR transducer.
EGR TUBE SERVICE3. 0L ENGINES
REMOVAL
(1) Remove EGR tube fl ange nuts from exhaust
(2) Remove EGR val ve nuts at i ntake mani fol d.
Remove EGR tube.
(3) Cl ean al l gasket surfaces and di scard ol d gas-
kets. Check for any si gns of l eakage or cracked sur-
faces. Repai r or repl ace as necessary.
INSTALLATION
(1) Loosel y i nstal l the EGR tube on the i ntake and
exhaust mani fol ds wi th new gaskets.
(2) Ti ghten EGR tube fl ange bol ts at the i ntake
mani fol d to 22 Nm (200 i n. l bs.) torque.
(3) Ti ghten EGR tube to exhaust mani fol d nuts to
EGR TUBE SERVICE3. 3/3. 8L ENGINES
REMOVAL
(1) Remove EGR tube attachi ng bol ts from i ntake
and exhaust mani fol ds (Fi g. 8).
(2) Cl ean i ntake and exhaust mani fol d gasket sur-
faces. Di scard ol d gasket.
(3) Check for si gns of l eakage or cracked surfaces
on ei ther mani fol ds or tube. Repai r or repl ace as nec-
essary.
Fig. 6 EGR System Service3.0L Engines Fig. 7 EGR System3.3/3.8L Engines
INSTALLATION
(1) Loosel y assembl e EGR tube and new gaskets
i nto pl ace on i ntake and exhaust mani fol ds.
(2) Ti ghten mounti ng bol ts to 22 Nm (200 i n. l bs.)
torque.
SPECIAL TOOLS
EMISSION CONTROL SYSTEM
Fig. 8 EGR Tube3.3/3.8L
Hose Clamp Pliers 6094
CONTENTS
page page
2. 0L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . 9
EXHAUST EMISSION CONTROLS
2. 5L DIESEL ENGINE . . . . . . . . . . . . . . . . . . . 5
2. 5L DIESEL ENGINE . . . . . . . . . . . . . . . . . . . 1
ON-BOARD DIAGNOSTICS2.5L DIESEL ENGINE
INDEX
page page
GENERAL INFORMATION
SYSTEM DESCRIPTION
2.5L DIESEL ENGINE . . . . . . . . . . . . . . . . . . . 1
DIAGNOSTIC TROUBLE CODES . . . . . . . . . . . . 2
GENERAL INFORMATION
SYSTEM DESCRIPTION2. 5L DIESEL ENGINE
The 2.5L di esel Powertrai n Control Modul e (PCM)
moni tors and control s many di fferent ci rcui ts i n the
fuel i njecti on pump and engi ne systems. I f the PCM
senses a probl em wi th a moni tored ci rcui t that i ndi -
cates an actual probl em, a Di agnosti c Troubl e Code
(DTC) wi l l be stored i n the PCMs memory, and even-
tual l y wi l l i l l umi nate the Di esel Gl ow Pl ug l amp con-
stantl y whi l e the key i s on. I f the probl em i s
repai red, or i s i ntermi ttent, the PCM wi l l erase the
DTC after 40 warm-up cycl es. A warm-up cycl e con-
si sts of starti ng the vehi cl e when the engi ne i s col d,
then the engi ne to warms up to a certai n tempera-
ture, and fi nal l y, the engi ne temperature fal l s to a
normal operati ng temperature, then the key i s
turned off.
Certai n cri teri a must be met for a DTC to be
entered i nto PCM memory. The cri teri a may be a
speci fi c range of engi ne rpm, engi ne or fuel tempera-
ture and/or i nput vol tage to the PCM. A DTC i ndi -
cates that the PCM has i denti fi ed an abnormal
si gnal i n a ci rcui t or the system. A DTC may i ndi cate
the resul t of a fai l ure, but never i denti fy the fai l ed
component di rectl y.
There are several operati ng condi ti ons that the
PCM does not moni tor and set a DTC for. Refer to
the fol l owi ng Moni tored Ci rcui ts and NonMoni tored
Ci rcui ts i n thi s secti on.
MONITORED CIRCUITS
The PCM can detect certai n probl ems i n the el ec-
tri cal system.
Open or Shorted Circuit The PCM can deter-
mi ne i f sensor output (whi ch i s the i nput to PCM) i s
wi thi n proper range. I t al so determi nes i f the ci rcui t
i s open or shorted.
Output Device Current Flow The PCM senses
whether the output devi ces are el ectri cal l y connected.
I f there i s a probl em wi th the ci rcui t, the PCM
senses whether the ci rcui t i s open, shorted to ground
(), or shorted to (+) vol tage.
NONMONITORED CIRCUITS
The PCM does not moni tor the fol l owi ng ci rcui ts,
systems or condi ti ons that coul d have mal functi ons
that resul t i n dri veabi l i ty probl ems. A DTC wi l l not
be di spl ayed for these condi ti ons.
Fuel Pressure: Fuel pressure i s control l ed by the
fuel i njecti on pump. The PCM cannot detect prob-
l ems i n thi s component.
Cylinder Compression: The PCM cannot detect
uneven, l ow, or hi gh engi ne cyl i nder compressi on.
Exhaust System: The PCM cannot detect a
pl ugged, restri cted or l eaki ng exhaust system.
Fuel Injector Malfunctions: The PCM cannot
determi ne i f the fuel i njector i s cl ogged, or the wrong
i njector i s i nstal l ed. The fuel i njectors on the di esel
engi ne are not controlled by the PCM, al though a
NS/GS EMISSION CONTROL SYSTEM 25 - 1
defecti ve fuel i njector sensor is monitored by the
PCM.
Vacuum Assist: Leaks or restri cti ons i n the vac-
uum ci rcui ts of vacuum assi sted engi ne control sys-
tem devi ces are not moni tored by the PCM.
PCM System Ground: The PCM cannot deter-
mi ne a poor system ground. However, a DTC may be
generated as a resul t of thi s condi ti on.
PCM Connector Engagement: The PCM cannot
determi ne spread or damaged connector pi ns. How-
ever, a DTC may be generated as a resul t of thi s con-
di ti on.
HIGH AND LOW LIMITS
The PCM compares i nput si gnal vol tages from each
i nput devi ce. I t wi l l establ i sh hi gh and l ow l i mi ts
that are programmed i nto i t for that devi ce. I f the
i nput vol tage i s not wi thi n speci fi cati ons and other
DTC cri teri a are met, a DTC wi l l be stored i n mem-
ory. Other DTC cri teri a mi ght i ncl ude engi ne rpm
l i mi ts or i nput vol tages from other sensors or
swi tches. The other i nputs mi ght have to be sensed
by the PCM when i t senses a hi gh or l ow i nput vol t-
age from the control system devi ce i n questi on.
On the fol l owi ng pages, a l i st of DTCs i s provi ded
for the 2.5L di esel engi ne. A DTC i ndi cates that the
PCM has recogni zed an abnormal si gnal i n a ci rcui t
or the system. A DTC may i ndi cate the resul t of a
fai l ure, but most l i kel y wi l l not i denti fy the fai l ed
component di rectl y.
ACCESSING DIAGNOSTIC TROUBLE CODES
A stored DTC can be di spl ayed through the use of
the DRB I I I scan tool . The DRB I I I connects to the
data l i nk connector. The data l i nk connector i s
l ocated under the i nstrument panel near bottom of
the steeri ng col umn (Fi g. 1).
ERASING TROUBLE CODES
After the probl em has been repai red, use the DRB
I I I scan tool to erase a DTC.
Generic Scan
Tool Code
DRB III Scan Tool Display
P1112 Boost Pressure Sensor Signal High
Boost Pressure Sensor Signal Low
Boost Pressure Sensor Supply High
Boost Pressure Sensor Supply Low
Boost Pressure Sensor Plausibility
P0110 Intake Air Temperature Sensor Signal High
Intake Air Temperature Sensor Signal Low
P1685 Immobilizer Signal Lost
Invalid SKIM Message
P0115 Temperature of Engine Coolant SRC High Exceeded
Temperature of Engine Coolant SRC Low Exceeded
P0180 Fuel Temperature Sensor SRC High Exceeded
Fuel Temperature Sensor SRC Low Exceeded
P0400 EGR Open Circuit
EGR Short Circuit
P0500 Vehicle Speed Sensor PEC Frequency Too High
Vehicle Speed Sensor Signal SRC High Exceeded
Fig. 1 Data Link Connector LocationTypical
25 - 2 EMISSION CONTROL SYSTEM NS/GS
Generic Scan
Tool Code
P0725 Engine Speed Sensor Dynamic Plausibility
Engine Speed Sensor Over Speed Recognition
Engine Speed Sensor Static Plausibilty
P1105 Atmospheric Pressure Sensor SRC High Exceeded
Atmospheric Pressure Sensor SRC Low Exceeded
P1201 Needle Movement Sensor SRC High Exceeded
Needle Movement Sensor SRC Low Exceeded
P1220 Fuel Quantity Actuator Neg. Gov. Deviation Cold
Fuel Quantity Actuator Neg. Gov. Deviation Warm
Fuel Quantity Actuator Pos. Gov. Deviation Cold
Fuel Quantity Actuator Pos. Gov. Deviation Warm
P1225 Control Sleeve Sensor Signal High Exceeded
Control Sleeve Sensor Start End Pos. Not Attained
Control Sleeve Sensor Stop End Pos. Not Attained
P1230 Timing Governing Negative Governor Deviation
Timing Governing Positive Governor Deviation
P1515 Accelerator Pedal Sensor Signal High Exceeded
Accelerator Pedal Sensor Signal Low Exceeded
Accelerator Pedal Sensor Signal PWG Plaus With Low Idle Switch
Accelerator Pedal Sensor Signal PWG Plaus With Potentiometer
P1600 Battery Voltage SRC High Exceeded
P1605 Terminal #15 Plausibility After Startup
P1610 Regulator Lower Regulator Limit
Regulator Upper Regulator Limit
P1615 Microcontroller Gate-Array Monitoring
Microcontroller Gate-Array Watchdog
Microcontroller Prepare Fuel Quantity Stop
Microcontroller Recovery Was Occurred
Microcontrller Redundant Overrun Monitoring
P1630 Timing Solenoid Valve Controller Open Circuit
Timing Solenoid Valve Controller Short Circuit
P1635 Glow Relay Controller Open Circuit
Glow Relay Controller Short Circuit
P1650 Diagnostic Lamp Open Circuit
Diagnostic Lamp Short Circuit
P1655 A/C Control Short Circuit
A/C Control Open Circuit
P1660 Redundant Emer. Stop Plausibility In After-Run
Redundant Emer Stop Powerstage Defective
P1665 Cruise Status Indicator Lamp Short Circuit
P1680 EEPROM Plausibility Checksum Error for Adj.
EEPROM Plausibility Checksum Error in CC212
EEPROM Plausibility Communication With EEPROM
EEPROM Plausibility Func. Switch Wrong or Missing
Generic Scan
Tool Code
EEPROM Plausibility Ver Number Not Corresponding
P1685 Vehicle Theft Alarm Code Line Breakdown
P1690 Fan Control Open Circuit Fan #1
Fan Control Open Circuit Fan #2
Fan Control Short Circuit Fan #1
Fan Control Short Circuit Fan #2
P1695 A/C System Pressure Sensor Signal High Exceeded
A/C System Pressure Sensor Signal Low Exceeded
A/C System Pressure Supply Signal High Exceeded
A/C System Pressure Supply Signal Low Exceeded
P1703 Brake Signal Plaus With Redundant Contact
P1740 Clutch Signal Plausibilty
P1725 Inductive Aux. Speed Sensor Dynamic Plausibilty
Inductive Aux. Speed Sensor Overspeed Recognition
Inductive Aux Speed Sensor Plausibilty
Inductive Aux. Speed Sensor Static Plausibilty
EXHAUST EMISSION CONTROLS2.5L DIESEL ENGINE
INDEX
page page
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
VACUUM HOSE ROUTING SCHEMATIC . . . . . . 5
EGR GAS FLOW TEST . . . . . . . . . . . . . . . . . . . 6
ELECTRIC VACUUM MODULATOR (EVM)
TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
EGR TUBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
EGR VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
ELECTRIC VACUUM MODULATOR (EVM) . . . . . 7
SPECIFICATIONS
TORQUE CHART2.5L DIESEL . . . . . . . . . . . . 8
VACUUM HOSE ROUTING SCHEMATIC
Vacuum for the EGR system i s suppl i ed by the
i nternal engi ne mounted vacuum pump. Refer to
EGR System Operati on for vacuum pump i nforma-
ti on. Vacuum harness routi ng for emi ssi on rel ated
components i s di spl ayed i n (Fi g. 1).
EXHAUST GAS RECIRCULATION (EGR) SYSTEM
GENERAL INFORMATION
The EGR system reduces oxi des of ni trogen (NOx)
i n the engi ne exhaust. Thi s i s accompl i shed by al l ow-
i ng a predetermi ned amount of hot exhaust gas to
reci rcul ate and di l ute the i ncomi ng fuel /ai r mi xture.
A mal functi oni ng EGR system can cause engi ne
stumbl e, sags or hesi tati on, rough i dl e, engi ne stal l -
i ng and poor dri veabi l i ty.
EGR SYSTEM OPERATION
The system consi sts of:
An EGR val ve assembl y. The val ve i s l ocated
behi nd the i ntake mani fol d (Fi g. 2).
Fig. 1 Typical Hose Routing
Fig. 2 EGR Valve and Tube Location
An EGR Sol enoi d. The EGR sol enoi d i s l ocated
i n the engi ne compartment next to the PDC (Fi g. 3).
The EGR sol enoi d opens and cl oses the vaccum sup-
pl y that opens and cl oses the EGR val ve. The
amount of ti me the EGR sol enoi d i s hel d open i s con-
trol l ed by the PCM. Thi s i s referred to as the on
ti me of the EGR val ve.
An EGR tube (Fi g. 2) connecti ng a passage i n
the EGR val ve to the rear of the exhaust mani fol d.
The vacuum pump, whi ch suppl i es vacuum for
the EGR Sol enoi d val ve. Thi s pump al so suppl i es
vacuum for operati on of the power brake booster. The
pump i s l ocated i nternal l y i n the front of the engi ne
bl ock (Fi g. 4) and i s dri ven by the crankshaft gear.
Vacuum l i nes and hoses to connect the vari ous
components.
When the PCM suppl i es a on or off si gnal to the
EGR Sol enoi d by groundi ng the ci rcui t, EGR system
operati on starts to occur. The PCM wi l l moni tor var-
i ous engi ne condi ti ons and determi ne when to suppl y
and remove thi s ground si gnal . Some of the engi ne
condi ti ons that are moni tored are the engi ne cool ant
temperature, throttl e posi ti on and engi ne speed sen-
sors.
When the ground si gnal i s suppl i ed to the EGR
Sol enoi d, vacuum from the vacuum pump wi l l be
al l owed to pass to the EGR val ve vi a a connecti ng
hose.
Exhaust gas reci rcul ati on wi l l begi n i n thi s order
when:
The PCM determi nes that EGR system opera-
ti on i s necessary.
The engi ne i s runni ng to operate the vacuum
pump.
A ground si gnal i s suppl i ed to the EVM.
Vacuum passes to the EGR val ve.
The i nl et seat (poppet val ve) at the bottom of
the EGR val ve opens to di l ute and reci rcul ate
exhaust gas back i nto the i ntake mani fol d.
The EGR system wi l l be shut down by the PCM
after 60 seconds of conti nuous engi ne i dl i ng to
i mprove i dl e qual i ty.
EGR GAS FLOW TEST
Use the fol l owi ng test procedure to determi ne i f
exhaust gas i s fl owi ng through the EGR val ve. I t can
al so be used to determi ne i f the EGR tube i s pl ugged,
or the system passages i n the i ntake or exhaust man-
i fol ds are pl ugged.
EGR system.
The engi ne must be started, runni ng and warmed
to operati ng temperature for thi s test.
(1) Al l EGR val ves are equi pped wi th a vacuum
suppl y fi tti ng l ocated on the EGR val ve vacuum
motor (Fi g. 2).
(2) Di sconnect the rubber hose from the vacuum
suppl y fi tti ng (Fi g. 2).
(3) Connect a handhel d vacuum pump to thi s fi t-
ti ng.
Fig. 3 EGR Solenoid
Fig. 4 Internal Vacuum Pump
(5) Sl owl y appl y 10 i nches of vacuum to the fi tti ng
on the EGR val ve motor. Vacuum shoul d hol d steady
at 10 i nches. I f not, repl ace the EGR val ve. I f vac-
uum hol ds steady at 10 i nches, proceed to next step.
(6) Whi l e appl yi ng vacuum, and wi th the engi ne
runni ng at i dl e speed, the i dl e speed shoul d drop, a
rough i dl e may occur, or the engi ne may even stal l .
Thi s i s i ndi cati ng that exhaust gas i s fl owi ng through
the EGR tube between the i ntake and exhaust man-
i fol ds.
(7) I f the engi ne speed di d not change, the EGR
val ve may be defecti ve, the EGR tube may be
pl ugged wi th carbon, or the passages i n the i ntake
and exhaust mani fol ds may be pl ugged wi th carbon.
(a) Remove EGR val ve from engi ne. Refer to
EGR Val ve Removal i n thi s group.
(b) Appl y vacuum to the vacuum motor fi tti ng
and observe the stem on the EGR val ve. I f the
stem i s movi ng, i t can be assumed that the EGR
val ve i s functi oni ng correctl y. The probl em i s i n
ei ther a pl ugged EGR tube or pl ugged passages at
the i ntake or exhaust mani fol ds. Refer to step (c).
I f the stem wi l l not move, repl ace the EGR val ve.
(c) Remove the EGR tube between the i ntake
and exhaust mani fol ds. Check and cl ean the EGR
tube and i ts rel ated openi ngs on the mani fol ds.
Refer to EGR Tube i n thi s group for procedures.
Do not attempt to cl ean the EGR val ve. I f the
val ve shows evi dence of heavy carbon bui l dup near
the base, repl ace i t.
ELECTRIC VACUUM MODULATOR (EVM) TEST
VACUUM TEST
Wi th the engi ne runni ng, di sconnect the vacuum
suppl y l i ne at the fi tti ng on the EVM. Mi ni mum vac-
uum shoul d be no l ess than 20 i nches. I f vacuum i s
l ower, check for l eaks i n vacuum suppl y l i ne. I f l eaks
cannot be found, check for l ow vacuum at vacuum
pump. Refer to Group 5, Brake System for proce-
dures.
EGR VALVE
REMOVAL
(1) Remove the rubber hose from turbocharger to
metal tube.
(2) Di sconnect vacuum l i ne at EGR val ve vacuum
suppl y fi tti ng (Fi g. 2).
(3) Loosen the tube fi tti ng at exhaust mani fol d end
of EGR tube (Fi g. 2).
(4) Remove the two bol ts retai ni ng the EGR tube
to the si de of EGR val ve (Fi g. 2).
(5) Remove the two EGR val ve mounti ng bol ts
(Fi g. 2) and remove EGR val ve.
(6) Di scard both of the ol d EGR mounti ng gaskets.
INSTALLATION
(1) Cl ean the i ntake mani fol d of any ol d gasket
materi al .
(2) Cl ean the end of EGR tube of any ol d gasket
materi al .
(3) Posi ti on the EGR val ve and new gasket to the
i ntake mani fol d.
(4) I nstal l two EGR val ve mounti ng bol ts. Do not
ti ghten bol ts at thi s ti me.
(5) Posi ti on new gasket between EGR val ve and
EGR tube.
(6) I nstal l two EGR tube bol ts. Ti ghten al l four
mounti ng bol ts to 23 Nm (204 i n. l bs.).
(7) Ti ghten EGR tube fi tti ng at exhaust mani fol d.
(8) Connect vacuum l i ne to EGR val ve.
(9) I nstal l the rubber hose from turbocharger to
metal tube.
EGR TUBE
The EGR tube connects the EGR val ve to the rear
of the exhaust mani fol d (Fi g. 2).
REMOVAL
(1) Remove rubber hose from turbocharger to
metal tube.
(2) Remove two EGR tube mounti ng bol ts at EGR
val ve end of tube (Fi g. 2).
(3) Loosen fi tti ng at exhaust mani fol d end of tube
(Fi g. 2).
(4) Remove EGR tube and di scard ol d gasket.
(5) Cl ean gasket mati ng surfaces and EGR tube
fl ange gasket surfaces.
(6) Check for si gns of l eakage or cracked surfaces
at both ends of tube, exhaust mani fol d and EGR
val ve.
INSTALLATION
(1) I nstal l a new gasket to EGR val ve end of EGR
tube.
(2) Posi ti on EGR tube to engi ne.
(3) Loosel y ti ghten fi tti ng at exhaust mani fol d end
of tube.
(4) I nstal l 2 mounti ng bol ts at EGR val ve end of
tube. Ti ghten bol ts to 23 Nm (204 i n. l bs.) torque.
(5) Ti ghten fi tti ng at exhaust mani fol d end of tube.
(6) I nstal l hose from turbocharger to metal tube.
ELECTRIC VACUUM MODULATOR (EVM)
The EVM (EGR Duty Cycl e Purge Sol enoi d) i s
mounted to the si de of the PDC (Fi g. 6).
REMOVAL
cabl e fi rst.
(2) Remove 2 screws hol di ng PDC to bracket,
swi ng out of way.
(5) Di sconnect two vacuum hoses at EVM (Fi g. 6).
(6) Remove mounti ng screws of EVM.
(7) Remove the EVM to gai n access to the EVM
el ectri cal connector.
(8) Remove el ectri cal connector at EVM.
INSTALLATION
(1) I nstal l el ectri cal connector to EVM.
(2) I nstal l EVM and ti ghten mounti ng screws.
(3) Connect vacuum hoses.
(4) I nstal l PDC to bracket and ti ghten mounti ng
screws.
(6) Connect battery cabl es posi ti ve fi rst.
SPECIFICATIONS
TORQUE CHART2. 5L DIESEL
Description Torque
EGR Val ve Mounti ng Bol ts . . . . . . . . . . . . . . 23 Nm
(204 i n. l bs.)
EGR Tube Mounti ng Bol ts . . . . . . . . . . . . . . 23 Nm
(204 i n. l bs.)
EVM (El ectri c Vacuum
Modul ator) Mounti ng Bol t . . . . 2 Nm (20 i n. l bs.)
Fig. 6 EVM Location
EMISSION CONTROL SYSTEM2.0L ENGINE
INDEX
page page
GENERAL INFORMATION
POSITIVE CRANKCASE VENTILATION SYSTEM
(PCV) SYSTEM2.0L ENGINE . . . . . . . . . . . . 9
EGR TUBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
EGR VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
GENERAL INFORMATION
GENERAL INFORMATION
The emi ssi on control system for the 2.0L engi ne
functi ons the same as the systems for the 2.4/3.0/3.3/
3.8L engi nes. Refer to group 25 for more i nformati on
about Di agnosti c Troubl e Codes and other system
features.
POSITIVE CRANKCASE VENTILATION SYSTEM
(PCV) SYSTEM2. 0L ENGINE
The PCV System for 2.0L engi nes functi on the
same as PCV systems for 2.4/3.0/3.3/3.8L engi nes.
Refer to group 25 for more i nformati on.
EGR VALVE
I f the EGR system operates i ncorrectl y, repl ace the
enti re EGR val ve and transducer together. The EGR
val ve and el ectri cal transducer (EET) are cal i brated
together.
REMOVAL
The EGR val ve attaches to the rear of the cyl i nder
head (Fi g. 2). EGR transducer i s attached to the ai r
i nl et duct.
(1) Remove EGR transducer from ai r i nl et duct.
(2) Di sconnect vacuum suppl y tube from EGR
transducer sol enoi d.
(3) Di sconnect el ectri cal connector from sol enoi d.
(4) Remove ai r i nl et duct.
(5) Remove EGR tube to EGR val ve screws.
(6) Remove EGR val ve mounti ng screws. Remove
EGR val ve and transducer.
(7) Cl ean gasket surfaces. Di scard ol d gaskets. I f
necessary, cl ean EGR passages.
Fig. 1 PCV System2.0L
INSTALLATION
(1) Loosel y i nstal l EGR val ve wi th new gaskets.
(2) Fi nger ti ghten EGR tube fasteners.
(3) Ti ghten EGR tube fasteners to 11 Nm (95 i n.
l bs.) torque.
(4) Ti ghteni ng EGR val ve mounti ng screws to 22
(5) I nstal l ai r i nl et duct.
(6) Connect vacuum suppl y tube to sol enoi d.
(7) Attach el ectri cal connector to sol enoi d.
(8) I nstal l EGR transducer onto ai r i nl et duct.
EGR TUBE
The EGR tube attaches to the i ntake mani fol d pl e-
num bel ow the throttl e body and EGR val ve.
REMOVAL
(1) Remove screws attachi ng EGR tube to i ntake
(2) Remove EGR tube to EGR val ve screws.
(3) Remove EGR tube. Cl ean gasket surface on the
EGR val ve. Wi pe cl ean the grommet on the i ntake
mani fol d.
INSTALLATION
The rubber grommet that seal s the EGR tube to
i ntake mani fol d connecti on i s reusabl e.
(1) Loosel y i nstal l the EGR tube and fasteners.
(2) Ti ghten the EGR tube to i ntake mani fol d pl e-
num screws to 11 Nm (95 i n. l bs) torque.
(3) Ti ghten the EGR tube to EGR val ve screws to
TORQUE
Description Torque
EGR val ve to cyl . head . . . . . . . 22 Nm (200 i n. l bs.)
EGR tube to EGR val ve . . . . . . . . . . . 11 (95 i n. l bs.)
EGR tube to i ntake mani fol d . . . 11 Nm (95 i n. l bs.)
Fig. 2 EGR System
Fig. 3 EGR Tube Stud Bolts

Chrysler Voyager Service Manual GS 1999-1996

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Chrysler Voyager Service Manual GS 1999-1996

Uploaded by

Copyright:

Available Formats

CHRYSLER

8E - 10 INSTRUMENT PANEL AND SYSTEMS NS

You might also like